WO2010076795A1

WO2010076795A1 - Non-flat photobioreactor

Info

Publication number: WO2010076795A1
Application number: PCT/IL2009/001231
Authority: WO
Inventors: Avraham Avidan
Original assignee: Avraham Avidan
Priority date: 2009-01-02
Filing date: 2009-12-30
Publication date: 2010-07-08

Abstract

The present invention is directed to a non-flat photobioreactor device that comprises a structural element composed of at least a solid frame and a pattern of non continuous repeating bars in either a vertical or horizontal position said structural element is adapted for supporting a flexible element; and a flexible element adapted for holding liquid medium for photosynthetic organism cultivation; Wherein, upon filling said flexible element with liquid medium, said flexible element exceeds said non continuous bars of structural element to thereby create a non flat surface area with repeating curvature. The present invention is further directed to a novel real time horizontal scale up system and to a novel effective harvesting system.

Description

Non-Flat Photobioreactor

FIELD OF THE INVENTION

The present invention is related to a modular and scalable non flat photobioreactor for large scale production of photosynthetic organisms such as marine and fresh water microalgae, macroalgae and cyanobactiria. The present invention is further related to a novel horizontal real-time scale up system, and to an efficient harvesting system allowing harvesting of cultivated photosynthetic organisms and / or products produced by the organisms during cultivation. The present invention is further related to purification of polluted air by cultivating photosynthetic organisms such as algae, which are capable of reducing carbon dioxide (CO₂) and/or nitrogen oxide (NO_x) and/or sulfur oxide (SO_x).

BACKGROUND

In recent times, algal biotechnology has received considerable attention, specifically in regards to commercial applications. The ability of simple microorganisms such as green, blue-green and red algae to produce useful metabolites through photosynthetic processes holds great world interest.

By utilizing both carbon dioxide and light energy, microalgae are able to produce many useful products. In pharmaceutical applications, microalgae can produce antibodies, sterols (building blocks for hormones), antimicrobials and anticancer compounds. Microalgae can also be used in human and animal nutrition as they contain long-chain polyunsaturated fatty acids (PUFAs), vitamins, minerals and antioxidants such as β-carotene and astaxanthin. These photosynthetic microorganisms are also cultivated for cosmetic pigments and dyes such as carotenoids and biloproteins. In environmental engineering applications, microalgae are utilized in bioremediation and wastewater treatment facilities. Due to recent world awareness, microalgae have been suggested as a means to produce biofuel and to sequester CO₂, a greenhouse gas that is an essential reactant in the photosynthetic process. Compared to other terrestrial crops, microalgae photosynthetic efficiency and therefore growth rate is staggering. Microalgae are cultivated in photobioreactors, a type of bioreactor that houses photosynthetic organisms in a liquid culture medium. While algae transform light energy into chemical energy more efficiently than other terrestrial crops, large-scale photobioreactors have not been optimized to deliver quality products at a reasonable cost.

Photobioreactors have been tested in a variety of applications. When deciding upon a system, various factors must be considered. These factors include the strain of algae, water availability, nutrients, climate (for outdoor systems), the quality and quantity of product, and the cost of land, labor, energy etc. The two major types of photobioreactors that have been developed are open and enclosed systems, each presenting their own advantages and disadvantages (Ugwu et al., 2007).

Open systems present daunting disadvantages. For example, the culture is exposed leaving it more vulnerable to contamination by insects, environmental pollutants and microorganisms such as bacteria, amoebas and rotifers. Highly selective algal species such as Chlorella can dominate a medium and suppress contamination. However, the production of other microalgae strains, more prawn to contaminations, in these systems is mostly impractical as they yield low amounts of microalgae biomass due to decreased growth rates. Furthermore, open photobioreactors make it nearly impossible to control growth parameters. They have little to no control of light intensity, temperature and pH, and fail to efficiently utilize CO₂ as it easily escapes into the atmosphere.

An example of an open system is the large pond, which illustrates a type of culture pool or tank is provided by Boussiba et al., 1988. Generally, such systems require relatively low initial and operational capital input. However, only the top portion of the pond is illuminated efficiently creating a very poor illuminated surface area to volume ratio. Open ponds also require a great deal of water (due to evaporation) and flat land, and in turn, produce relative dilute concentrations of biomass. Furthermore, these systems consume tremendous amounts of energy in their attempts to effectively stir, pump and centrifuge the immense volume. Due to the various issues associated with open photobioreactors, there is a need for an closed system.

Closed photobioreactors greatly decrease the probability of contamination and allow for better control of growth parameters. Examples of closed photobioreactor are described in US 2007/0264708 Al and US2008/0086939 Al. However, a major drawback of closed photobioreactor designs is the high initial and operational costs. In the lab, complex photobioreactor designs present some advantages, but when attempting to scale-up the system, their cost and complexity render them commercially unviable. Another issue with many closed photobioreactors, as opposed to open systems, is the removal and cleaning of adhered internal surface microalgae. This issue can create tremendous photo-efficiency issues as well as dramatically increase maintenance costs. Most closed photobioreactors fall under several categories, namely tube, vertical-column, flat plate, and fermenter reactors.

A closed cultivation system built from transparent tubes is illustrated in GB-A- 2118572. By reducing the light path, this design allows for better light penetration. Such systems therefore yield relatively high concentrations of biomass as compared to open photobioreactors. However, a major drawback of such systems is the lack of scalability. When placed horizontally, these systems require massive amounts of land. Due to the tubes relatively complex structure and size, initial and operational costs severely limit mass scale implementation. Other known drawback of horizontal tube photobioreactors is the necessary mixing by large pumps. These flow control systems consume a great deal of energy, capital and operational expenses. Yield issues have also been discovered when oxygen gas from the result of photosynthesis builds up inside the tube, inhibiting photosynthesis. Furthermore the challenge of assembling many units for mass production of algae is enormous.

The closed vertical column photobioreactor are bubble and airlift circulated, and can be of draft and split cylinder nature. Microalgae suspended in medium are driven up the vertical column, and settle back down through a separate path. This efficient circulation method proves to be effective as biomass concentration and growth rates are similar to that of narrow tubular systems (Ugwu et al., 2007). Also, due to air lift technology, low energy consumption is required. Drawbacks of this system include a small illumination of surface area, the requirement of sophisticated construction materials, and algal sheer stress (US 5,534,417).

A closed flat plate photobioreactor composed of narrow perpendicular panels (as described by Ramos de Ortega, A., Roux, J.C., 1986) was designed for high surface area to volume ratio. Flat plate photobioreactor are known for their high productivity and uniform light distribution. By increasing the height of the system, the flat plate design allows for an efficient use of land. Also, in the presence of a bubble column, no high powered pump is required. Due to the necessity to manufacture, support and install many compartments, scale up of flat plate reactors has yet been unsuccessful.

Many simple photobioreactors possess an intrinsic disadvantage due to a low illuminated surface area to volume ratio, poorly exposing microalgae to sunlight. To overcome this, many reactors have introduced sophisticated artificial lighting systems ranging from a fully submersed florescent tubes to optical fibers channeling natural sunlight (see: US005104803 A). These methods are of high capital requirement, restricting their use mostly to laboratory scales. As culture systems have usually been designed for either indoor or outdoor use, issues arise when outdoor systems are brought indoors and vice versa as light utilization is not optimized for the change in environment.

Due to innate disadvantages in microalgae production using both closed systems (i.e. high initial and operational costs) and open systems (i.e. contamination and low productivity), microalgae cultivation has been limited to producing only high margin products (e.g. astaxantin, cosmetics and human food additives). In order to implement microalgae production for relatively low cost applications (biofuel, CO₂ sequestration, biomass, animal feed, etc.), (Richmond, Amos (2003). Handbook of Microalgal Culture. Biotechnology and Applied Phycology.), there exists a need for an efficient, economical, scalable, closed photobioreactor aimed for large scale production of microalgae. Additional references that may be relevant to the present invention are listed below: WO 2005/006838; US 2009/0053762; WO 2008/135991 A2; WO 2008/079724 A2

It is the aim of the present invention to provide a novel photobioreactor that will solve many of the issues described above. By utilizing a non-flat photobioreactor (NF PBR), the present invention contains a high surface area to volume ratio providing greatly improved illumination and allowing for the production of high concentrations of photosynthetic organisms. The present invention further provides a novel real time horizontal scale up system and a novel harvesting system allowing extraction of a high concentration of at least one desired product along with a minimum amount of culture liquid medium.

SUMMARY OF THE INVENTION

This summary section of the patent application is intended to provide an overview of the subject matter disclosed herein, in a form lengthier than an "abstract", and should not be construed as limiting the disclosure to any features described in this summary section.

In accordance with the present invention, a non-flat photobioreactor device (NF PBR) is provided. The NF PBR device comprising: a structural element composed of at least a solid frame and a pattern of non continuous repeating bars in either a vertical or horizontal position said structural element is adapted for supporting a flexible element; and a flexible element adapted for holding liquid medium for photosynthetic organism cultivation, wherein, upon filling said flexible element with liquid medium, said flexible element exceeds said non continuous bars of structural element to thereby create a non flat surface area with repeating curvature. The flexible element may be either translucent or transparent. The non-flat photobioreactor device may further comprise a real time horizontal scale up system. The horizontal scale up system provided herein, comprises at least one of the following components: mechanical bars, magnetic bars, electromagnetic bars, solid plate and bar, inflatable elements, a ring like valve, and a slider. These components are functionally adapted to allow sealing of the flexible element by applying pressure on the flexible element to thereby restrict said liquid medium for cultivation of photosynthetic organisms to a defined section of said flexible element. The components are added/subtracted or re-positioned along the flexible element in a gradual and controllable manner to allow either a larger or a smaller portion of the flexible element to be filled with liquid medium, thereby increasing or decreasing an operating volume as needed. The terms "operating volume" and "operational volume" as used herein are both meaning the same and refers to the volume of the flexible element containing a liquid medium for cultivation of photosynthetic organisms together with at least one photosynthetic organism. The non-flat photobioreactor device according to the present invention may further comprise a harvesting system adapted to allow extraction of a high concentration of at least one desired product along with a minimum amount of said liquid medium. Extraction of a high concentration of at least one product along with a minimum amount of liquid medium is namely achieved by dividing flexible element into at least two uneven parts. Such division may be conducted either after precipitation or floatation of a desired product. The division of the flexible element into at least two uneven parts may be conducted by using at least one of the following components: mechanical bars, magnetic bars, electromagnetic bars, solid plate and bar, and inflatable elements. These components are adapted to be positioned horizontally from both outer sides of the flexible element, either near the top portion or near the bottom, and to apply pressure towards the center of the flexible element to thereby allow division of flexible element into at least two uneven parts. The desired product in accordance with the present invention can be either one of a photosynthetic organism cultivated in the liquid medium of the NF PBR of the invention or a material produced by a photosynthetic organism cultivated in the liquid medium, or a mixture thereof. In a specific embodiment of the invention, a product such as oil produced by microalgae needs to be extracted. In such scenario, extraction is achieved by simply collecting the product (e.g. the oil) that naturally floats to upper part of the liquid medium via a draining outlet located at the top portion of the NF PBR device. Thus, the harvesting system provided herein is functionally adapted to allow efficient extraction of a product by only removing a small portion of the liquid medium (compared to the total operating volume) that contains a high concentration of said product.

The NF PBR device of the invention further comprises an aeration system. The aeration system comprises at least a gas source, a gas inlet, and aeration tubing. The aeration tubing may be an integral part of the flexible element or an independent part separated thereof that is inserted into the flexible element. Integral aeration tubing may be created in various methods. One way is to create horizontal non continuous heat stamping near the bottom of said flexible element. Aeration is achieved by injecting air through an air inlet bellow the heat stamping thus, functionally creating a tube like structure. The injected air goes up to the liquid medium through points where heat stamps are missing. Aeration system in accordance with embodiments of the invention may further be adapted to provide temperature regulation of the liquid medium for cultivation by injecting heated or chilled air.

The non-flat photobioreactor device according to the invention may further comprise a heat exchange unit, an artificial lighting source inside or outside the flexible element, supporting components adapted to mechanically stabilize the structural element upon filling flexible element with a liquid medium, and/or a tilting mechanism.

Photosynthetic organisms in accordance with the present invention are selected from the group consisting but not limited to: marine microalgae, marine macroalgae, fresh water microalgae, fresh water macroalgae, and cyanobactiria.

In accordance with the present inventions, either one of systems mentioned above including: scale up system, harvesting system, aeration system, tilting system, artificial lighting system and heat exchange unit may be operated manually or automatically, or semi-automated.

The present invention is further aimed to provide a photobioreactor device for photosynthetic organisms cultivation comprising: a non flat structure adapted to increase surface area to volume ratio; a real time horizontal scale up system adapted to allow increasing or decreasing operating volume of a culture liquid medium as needed; and a harvesting system adapted to allow extraction of a high concentration of at least one desired product along with a minimum amount of said culture liquid medium.

The non flat structure of such photobioreactor device comprises: a structural element composed of at least a solid frame and a pattern of non continuous repeating bars in either a vertical or horizontal position said structural element is adapted for supporting a flexible element; and a flexible element adapted for holding a liquid medium for photosynthetic organisms cultivation; Wherein, upon filling the flexible element with liquid medium it exceed the non continuous bars of structural element to thereby create a non flat surface area with repeating curvature. In such embodiment, the flexible element is either transparent or translucent.

The real time horizontal scale up system may comprise at least one of the following components: mechanical bars, magnetic bars, electromagnetic bars, solid plate and bar, inflatable elements, a ring like valve, and a slider. The components are adapted to allow sealing of said flexible element by applying pressure on said flexible element to thereby restrict the liquid medium for cultivation of photosynthetic organisms to a defined section of flexible element. The components are functionally added/subtracted or re-positioned along flexible element in a gradual and controllable manner to allow either a larger or a smaller portion of the flexible element to be filled with liquid medium, thereby increasing or decreasing the operating volume as needed.

The harvesting system of the photobioreactor provided herein is adapted to allow extraction of a high concentration of at least one product along with a minimum amount of liquid medium by dividing flexible element into at least two uneven parts. Division of the flexible element into at least two uneven parts is conducted either after precipitation or floatation of the desired product. The division of the flexible element is functionally conducted by at least one of the following components: mechanical bars, magnetic bars, electromagnetic bars, solid plate and bar, and inflatable elements. These components are adapted to be positioned horizontally from both outer sides of flexible element, either near the top portion or near the bottom, and to apply pressure towards the center of flexible element to thereby allow dividing of flexible element into at least two uneven parts. The desired product may be either one of a photosynthetic organism cultivated in the photobioreactor liquid medium or a material produced by a photosynthetic organism cultivated in the liquid medium, or both. The photobioreactor device described above may further comprise at least one of: an aeration system, artificial lighting system, tilting system, supporting components adapted for mechanically stabilizing the structural element, and a heat exchange unit. Each one of the systems mentioned including: scale up system, harvesting system, aeration system, artificial lighting system, tilting system and heat exchange unit may be operated manually or automatically, or semi-automatically.

The present invention is further aimed to provide a real time horizontal scale up system adapted to allow increasing or decreasing of an operating volume of a liquid medium for photosynthetic organisms' cultivation as needed, in any photobioreactor device that comprises a flexible chamber for holding an operating volume of liquid medium. The scale up system comprises at least one of the following components: mechanical bars, magnetic bars, electromagnetic bars, solid plate and bar, inflatable elements, a ring like valve, and a slider. These components are functionally adapted to allow sealing of the flexible chamber by applying pressure on the flexible chamber from both of its sides to thereby restrict liquid medium for cultivation of photosynthetic organisms to a defined section of the flexible chamber. These components are added/subtracted or re-positioned along the flexible chamber in a gradual and controllable manner to allow either a larger or a smaller portion of the flexible chamber to be filled with liquid medium, thereby increasing or decreasing an operating volume as needed.

A further aim of the present invention is to provide a harvesting system adapted to allow extraction of a high concentration of at least one desired product along with a minimum amount of a culture liquid medium in any photobioreactor device comprising a flexible chamber for holding culture liquid medium. Such harvesting system allows extraction of a high concentration of at least one desired product along with a minimum amount of culture liquid medium by dividing the flexible chamber into at least two uneven parts. Division of the flexible chamber into at least two uneven parts is conducted either after precipitation or floatation of the desired product, wherein, the desired product may be either one of a photosynthetic organism cultivated in the liquid medium or a material produced by a photosynthetic organism cultivated in said liquid medium, or both, and wherein, the photosynthetic organism is selected from the group consisting but not limited to: marine microalgae, marine macroalgae, fresh water microalgae, fresh water macroalgae, and cyanobactiria.

Division of the flexible chamber into at least two uneven parts may be conducted by at least one of the following components: mechanical bars, magnetic bars, electromagnetic bars, solid plate and bar, and inflatable elements. These components are adapted to be positioned horizontally from both outer sides of the flexible chamber, either near the top portion or near the bottom, and to apply pressure towards the center of the flexible chamber to thereby allow dividing of the flexible chamber into at least two uneven parts.

BRIEF DESCRIPTION OF THE DRAWINGS

Examples illustrative of embodiments of the disclosure are described below with reference to figures attached hereto. In the figures, identical structures, elements or parts that appear in more than one figure are generally labeled with the same numeral in all the figures in which they appear. Dimensions of components and features shown in the figures are generally chosen for convenience and clarity of presentation and are not necessarily shown to scale. Many of the figures presented are in the form of schematic illustrations and, as such, certain elements may be drawn greatly simplified or not-to-scale, for illustrative clarity. The figures are not intended to be production drawings. The figures depict only embodiments of the invention and thus should not be considered to be limiting the scope of the invention.

The figures (Figs.) are listed below. Figure 1 is a front view schematic illustration of a non flat photobioreactor

(NF PBR) device 100 in accordance with embodiments of the present invention.

Figure 2 is a front view schematic illustration of a NF PBR device 200 in accordance with another embodiment of the present invention.

Figure 3 is a top view schematic illustration the NF PBR device 100 of figure 1.

Figures 4 is a schematic front view illustration of an embodiment of an aeration system 60 in accordance with the present invention.

Figures 5Al, 5A2, 5Bl, 5B2, 5Cl and 5C2 are schematic close up side view cross sections (5A2, 5A2, 5Bl and 5B2 and side view (5Cl, 5C2) illustrations of various embodiments of harvesting system in opened and closed positions in accordance with the present invention.

Figure 6 is a schematic side view illustration of a scale up system slider in accordance with embodiment of the present invention.

DETAILED DESCRIPTION OF EMBODIMENT

In the following description, various aspects of a non flat photobioreactor will be described. For the purpose of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the device.

Although various features of the disclosure may be described in the context of a single embodiment, the features may also be provided separately or in any suitable combination. Conversely, although the disclosure may be described herein in the context of separate embodiments for clarity, the disclosure may also be implemented in a single embodiment. Furthermore, it should be understood that the disclosure can be carried out or practiced in various ways, and that the disclosure can be implemented in embodiments other than the exemplary ones described herein below. The descriptions, examples and materials presented in the description, as well as in the claims, should not be construed as limiting, but rather as illustrative. Terms for indicating relative direction or location, such as "right" and "left",

"up" and "down", "top" and "bottom", "horizontal" and "vertical", "higher" and "lower" "distal" and "proximal", and the like, may also be used, without limitation.

Reference is now made to the figures.

Figure 1 is a schematic front view illustration of a NF PBR device 100 in accordance with embodiments of the present invention. NF PBR device 100 comprises at least a cage-like hollow structural element 10 adapted for supporting and shaping a flexible element 40; a flexible element 40 adapted for holding culture liquid medium for photosynthetic organisms cultivation; and an aeration system 60 adapted to allow aeration of said culture liquid medium.

Structural element 10 may be shaped as a cage made of a solid frame 20 such as non deformable metals, plastic such as Perspex or any other material characterized by resistance to deformation and changes of volume; and a pattern of non continuous repeating vertical solid bars 22, from at least one side of solid frame 20, allowing light penetrating to said culture liquid medium inside flexible element 40. Alternatively, instead of solid bars tight wires may be used. Structural element 10 may be in a flat geometry or in a non flat geometry. The dimensions of structural element 10 as well as the length and thickness of solid frame 20 and solid bars 22 may vary according to the needs of use. Also, the distance between two adjacent bars 22 may vary. As illustrated in figure 1, the length of structural element 10 may be extended according to the needs and the length of flexible element 40 is adjusted accordingly. Preferably but not necessarily, the components of structural element 10 are translucent or transparent to thereby allow penetration of light into the culture medium inside flexible element 40, however, in most cases, they may also be opaque. In accordance with the present invention, flexible element 40 may be any flexible translucent or transparent means capable of being inserted inside structural element 10 such as bags made of plastic, nylon, laminate material, poly-laminate material, polyethylene, polyamide, PVC, etc, and adapted to hold a liquid medium for cultivation of photosynthetic organisms. Flexible element 40 may be a disposable element or it may be re-used. Thanks to the pliability nature of flexible element 40, and due to the pressure the liquid medium applies on flexible element 40 from its inner side and the pressure that structural element 10 applies on flexible element 40 from its outer side, flexible element 40 exceeds solid frame 20 in the spacing between bars 22 to thereby create a non-flat surface area with repeating curvature 26, forming a non-flat surface, that functionally allows a better light penetration inside said flexible element 40, and thus to the culture liquid medium, due to improved surface area to volume ratio. In accordance with the present invention, flexible element 40 may be in various dimensions. Preferably, the volume of flexible element 40 may range between 0.1-1000 cubical meters. In addition, as will be described in details hereinafter, while being used i.e. with a culture liquid medium inside of it, flexible element 40 may be in a fully unrolled position, i.e. spread out in its maximum volume, or it may be only partially unrolled i.e. released to a predetermined volume, while the rest of its volume is rolled up 44 on a rolling stick 71, or folded (not shown), ready to be released in a later stage upon the user desire to scale up the device volume in real time. Flexible element 40 may further comprise a liquid inlet 49 adapted to allow filling of flexible element 40 with an initial liquid volume at the beginning of use of device 100 and to re- fill flexible element 40 with liquid upon scale up of device 100 and/or following harvesting.

In one embodiment of the present invention, structural element 10 may be supported to allow mechanical stability to NF PBR device 100 by any mechanical supporting component such as without limiting supporting component 3, solid grid 17, and IT shaped bars 16, illustrated in figure 1. Additionally NF PBR device 100 may be elevated to thereby allow a convenient access for additional elements that may be comprised in NF PBR device 100 if such components are designed to be located at the bottom side of device 100. Examples of such component may be a harvesting draining outlet 36 of harvesting system 30, air inlet 66 of aeration system 60, and any other optional components as will be described hereinafter. It is clear to any person skilled in the art that supporting component 3 illustrated in figure 1 is merely an example, and any other supporting component capable of supporting and/or elevating structural element 10 from floor level is suitable for the purposes of the present invention. Additionally or alternatively, structural component 10 may be positioned in a manner that will allow it to tilt along the course of the day by any means such as a motor, in order to optimally position itself with the angle of the sun (not shown).

NF PBR device 100 further comprises an aeration system 60 adapted to allow aeration of an operating volume 46 in flexible element 40. Aeration system 60 may include a gas source 62 such as a filtered air and/or CO₂ source e.g. flue gas from a power plant. The terms "gas" and "air" as used herein for the purposes of the present invention are both mean the same. Gas source 62 may be connected to a pressure regulator 65. Additionally or alternatively, gas source 62 may also be connected to a system for balancing gas concentrations and/or temperature control (not shown); Aeration system 60 further comprises an air tubing 64. Air tubing 64 may be an integral part of flexible element 40 as will be described in details with reference to figures 2 and 4. Alternatively, air tubing 64 may be an independent part separated from flexible element 40. In such scenario air tubing 64 may be for example, a flexible or rigid tube with holes for gas discharge. The tube may be inserted into flexible element 40 near its bottom, for example, before being rolled up, or it may be pushed along with the scale up of the system in real-time. In both scenarios, air tubing 64 is designed to create a favorable circulation of the photosynthetic organisms, while supplying them with CO₂ to support growth. An example would be such that one or more points of air discharge will be located approximately at the middle of two adjacent bars 22. Alternatively, positioning of the air discharging points may be different from the one described above to thereby create better conditions for different strains. For example, macro-algae would have different requirements than micro-algae. The size and number of the holes in air tubing 64 may vary relative to the distance from gas inlet 66. For example, in near proximity to gas inlet 66 holes will be small as the gas pressure is high. The size of the holes may increase as the distance from gas inlet 66 will increase in order to compensate for the reduction in gas pressure and to allow homogeny in size of air bubbles 90. In accordance with the present invention, aeration system 60 may comprise multiple gas inlets to thereby allow better distribution of air especially in large size NF PBR devices. Aeration system 60 may further be used to help scrub the inner surfaces of flexible element 40 to thereby minimize algal attachment to flexible element 40 that may limit light penetration.

In accordance with the present invention, NF PBR device 100 may further comprise a horizontal scale-up system 70, represented in figure 1 as two vertical locking bars 72 located inside structural element 10, from each side of flexible element 40 and a connector 78 that is functionally adapted to keep bars 72 in locked position. When locking bars 72 are pressed against one another they restrict the part of flexible element 40 that is filled with culture liquid from its other part that is rolled 44 or unfolded (not shown) and awaiting for future use according to the needs. The means to press locking bars 72 against one another may be any mechanical or electrical means (e.g. bolt and nut, piston, lever, etc.) suitable for the above mentioned purpose (not shown). In order to scale up the part of flexible element filled with liquid i.e., to enlarge the operational volume, a portion of the rolled flexible element 44 is unrolled and the two scale-up locking bars 72 are repositioned to thereby allow a larger part of flexible element 40 to be filled with liquid medium thus, increasing operating volume 46 according to the needs. Despite that in the embodiments described herein, the rolled up flexible element is positioned inside structural element 10, it is clear that same concept of scale up could be achieved by positioning of the rolled up flexible element outside of structural element 10.

In accordance with the present invention, scale up system 70 may comprise more than two locking bars 72, with one or more apposing ridges located vertically inside structural element 10, one from each side of flexible element 40. Locking bars

72 may be in various shapes, sizes and may be made of various materials and operated by various mechanisms. For example, locking bars 72 may be solid elements, magnetic or electromagnetic bars that are pressed up against one another by any means such as but not limited to a mechanical force driven by motors or by electromagnets, inflatable elements as illustrated in figure 2 or a slider as illustrated in figure 6. In addition, the embodiments illustrated in figures 5 for harvesting bars may also function as scale up locking bars when positioned vertically. By forcing locking bars 72 together, liquid inside flexible element 40 is restricted to a predetermined volume. During scale up, locking bars 72 are repositioned either by sliding or by detachment and reattachment further down flexible element 40. It is also possible to position bars across the entire length of NF PBR device 100 and remove them as necessary to eliminate the need to reposition the original solid elements.

It should be clear to any person skilled in the art that horizontal scale-up system 70 may be composed of any means adapted to effectively section off one part of flexible element 40 from another without rupturing it, as well as a pump and tubing for inserting medium into NF PBR device 100. The mechanism for sectioning off flexible element 40 should further be adapted to be added/removed or repositioned allowing for real-time manual or automatic control of operating volume 46. The ability to control operating volume 46 in real-time may serve multiple purposes. For example, during initial inoculation, proliferation is possible only if the inoculum is not overly diluted by medium. This can be accomplished by introducing the inoculum to a relatively small operating volume by using a real-time scale up mechanism allowing for sectioning off a relatively small portion of flexible element 40. When the culture cells multiply and the photosynthetic organisms have reached a predetermined concentration, scale up system 70 can be repositioned or even removed. This allows for more medium to be pumped in, thereby expanding operating volume 46. In this way, concentrations are kept within a predetermined range allowing the organisms to remain in their more productive logarithmic phase. The horizontal scale up system 70 provided in accordance with the present invention as opposed to vertical scale up systems that are known in the art ensures that NF PBR device 100 will maintain constant physiological working conditions such as water pressure, circulation regime, mass transfer of gases such as CO₂ and O₂, etc for any desired operational volume and therefore making NF PBR device of the invention scalable. The horizontal scale up systems provided herein overcome the major drawbacks of vertical scale up systems, as vertical scale up systems require a lot more inoculum across the entire length of the photobioreactor. Also, in large vertical scale up systems, a lot more CO₂ is required and lost during the scale up process as it needs to be pumped across the entire length of the reactor. Scale up system 70 of the present invention may comprise a number of sets of scale-up locking bars 72 positioned on flexible element 40 and moving i.e. scaling up the device at different directions to significantly minimize the period of time required to scale up the entire NF PBR device 100.

In accordance with embodiments of the present invention, scale up system 70 may comprise one or more sliders. The term "slider" as used herein refers to a mechanism for sectioning off segments of flexible element 40 that can slide or move across the length of flexible element 40. A detailed description of an exemplary slider is provided in figure 6 below.

NF PBR device 100 of the present invention may further comprise a harvesting system 30, illustrated in figure 1 as two horizontal harvesting bars 32, located inside structural element 10, one from each side of flexible element 40 near its bottom. Alternatively, harvesting system 30 may be positioned at the upper part of NF PBR device 100 as illustrated in figure 2. The positioning of harvesting system 30 at the top or bottom of the device may be determined according to the desired product to be extracted. For example, when extracting microorganisms, the location of the harvesting bars is determined according to the favorable method of either floating or precipitating said strain. During cultivation of photosynthetic organisms, harvesting bars 32 are positioned against the vertical (or horizontal) solid bars 22 of structural element 10, in effect, not restricting flexible element 40 in anyway. During the initial stages of the harvesting process, the photosynthetic organisms undergo floatation or precipitation in order to locally increase the concentration of the photosynthetic organisms inside flexible element 40 near one of its edges (top or bottom). After floating or precipitating the organisms, the harvesting bars are pressed against one another, thereby sectioning off a high concentration of the photosynthetic organisms along with a minimum amount of liquid medium, from the large operating volume that contains a low concentration of photosynthetic organisms. The smaller volume/higher concentration of organisms then drained (or is pumped) through outlet 36 and is placed in another container (not shown) where post-processing (shearing the cells) occurs, thus, creating an efficient harvesting process. The same process may be conducted for extracting a product produced by photosynthetic organism into operating volume 46. After the desired content is removed from flexible element 40, harvesting bars 32 are returned back to their original location. The remaining contents left inside flexible element 40 is reused for further cultivation after additional medium is pumped back into flexible element 40 via liquid inlet 49. The entire process can then be repeated numerous times. Harvesting bars 32 may be designed and operated in a similar manner as illustrated in the above referring to locking bars 72 of scale up system 70 accept for the slider embodiment. Various embodiments of harvesting bars according to the present invention are illustrated in details in figures 5Al₅ 5A2, 5Bl, 5B2, 5Cl and 5C2.

Precipitation or floatation of photosynthetic organisms and/or products produced by such organism, before harvesting may be achieved in various common ways. Algal cultures can be concentrated by any means which cause cells to coagulate and precipitate either to the bottom or float to the surface of NF PBR device 100. One method of achieving this is through flocculation, or separating algae from the medium by forcing the algae to form clumps. Methods of flocculating the algae may include but are not limited to Froth Flocculation, Dissolved Air Flotation, or Auto-flocculation (Phoochinda W et al., 2004).

Froth Flotation separates the algae from the medium by adjusting pH and utilizing the bubbles of the aeration system to create a froth of algae that accumulates above liquid level which is then sectioned off and pumped out. Dissolved Air Flotation separates algae from its culture using features of both froth flotation and flocculation. It uses alum (several trivalent sulfates of metal such as aluminum, chromium, or iron and a univalent metal such as potassium or sodium, for example AlK(SOz_I)₂) to flocculate the algae in conjunction with the bubbles supplied by the aeration system. Auto-flocculation is a method of interrupting the carbon dioxide supply to an algal system which can cause the algae to flocculate on its own. It should be noted that most microalgae production technologies require that all the liquid and the organisms contained within the photobioreactor be pumped out for harvesting the contents. This process is inefficient as requires a tremendous amount of energy. The harvesting system provided in accordance with the present invention provides a tremendous advantage as it allows to section off and pump out only a relatively small portion of the operating volume (e.g. after microalgae has been flocculated and precipitated in the case of harvesting from the bottom of flexible element 40), thus, drastically reducing operational costs. Other microalgae production technology requires the use of membranes and filters to separate the biomass from the liquid medium. The present harvesting system is far superior as it can be repeated over and over again without the need to replace such expensive components.

The means to press harvesting bars 32 against one another may include any mechanical or electrical means (e.g. piston, lever, etc.) adapted to accomplish the mentioned purpose (not shown).

NF PBR device 100 of the present invention may further comprise a heat exchange unit 50. Changes in temperature between daylight and nighttime hours can be significant and therefore dramatically effect algal growth and productivity. In order to maintain optimum conditions, it may be needed to thermally regulate the liquid medium in the NF PBR device 100. This can be accomplished by any means to actively add or remove thermal energy from the liquid medium in NF PBR device 100. One way to accomplish this is through heat exchange accessories, for example by circulating heated or chilled liquid in tubing 54. Thermal energy is subsequently transferred into or out of heat exchange fluid which is then pumped out or re- circulated. In order to maintain constant temperatures within NF PBR device 100, the contents running through tubing 54 is actively controlled by a controller within said heat exchanged unit 50 (not shown). Additionally or alternatively, thermal regulation may be achieved by injecting preheated or chilled air through aeration system 60, or by flushing the sides of the NF PBR with hot or cold liquid.

One factor involved in controlling growth rate in any algal system is light availability. Generally, in photobioreactors, light decreases exponentially with distance from the irradiated surface of the photobioreactor. Thus, algae near the reactor surface are exposed to high photon flux density (PFD), which allows for high growth rates. However, at the core of the reactor, cells usually receive less light due to mutual shading, and therefore have a lower growth rate compared to algae growing near the reactor surface. In the case of dense cultures, or bioreactors with relatively low surface area to volume ratio, the reduction of light at the center of the bioreactor can be severe and as a consequence, drastically hindering algal growth rate.

Thus, in accordance with the present invention, photosynthetic organisms in operating volume 46 may be illuminated either by sunlight or by any artificial means. In such scenario, NF PBR device 100 may further comprise an artificial lighting system such as but not limited to fluorescents or Light Emitting Diodes (LEDs) (not shown). Alternatively, NF PBR device 100 may use both, sunlight during the day and artificial lighting system during the night hours or in cloudy days.

Another way of optimizing productivity of algae in operating volume 46 may be achieved by increasing the surface area to volume ratio of NF PBR device 100. This may be accomplished by designing the dimensions of device 100 so as to be thin in width in a manner that operating volume 46 will be preferably illuminated. However, efficient algal productivity in operating volume 46 is mainly achieved by the unique non flat structure of device 100, namely, by increasing the amount of curvatures on the sides of NF PBR device 100, in turn increasing surface area to volume ratio. Additionally, the bubbles released by aeration system 60 remove algae from the well illuminated wall surface of flexible element 40, and replaces it by other cells brought from the darker core of the culture liquid medium. Such circulation ensures that each liquid element and the algae suspended in it will spend a certain time near the wall, and then be removed from the vicinity of the wall and transported to the darker center of the liquid medium. This light dark cycle regime can be optimized for each specific photosynthetic organism strain and required product by adjusting the flow rate of aeration system 60, the number, size, shape and location of air discharge holes in air tubing 64, the spacing between bars 22 (or wires 224 illustrated in figure 2) and the width of structural element 10.

In accordance with the present invention, in order to avoid distortion of structural element 10, due to the pressure applied on it by the culture liquid medium inside flexible element 40, restraining Il (pi) shaped bars 16 may be placed on top of the upper and lower parts of structural element 10 and/or on its sides. The Fl-shaped bars 16 are adapted to keep the spacing between the two faces of structural element 10 along with solid bars 22 at a constant spacing. To support flexible element 40 elevated above the ground level, solid grid 17 or any other solid element suitable for such purpose, may be placed at the bottom of structural element 10.

In accordance with embodiments of the present invention structural element 10 may be designed in any desirable length, width or height. Accordingly, flexible element 40 that is inserted into it may be one unit or multiple units standing vertically next to each other, wherein each unit is controlled by one or more of the systems described in the above. Alternatively, NF PBR device 100 may comprise one flexible element 40 going through a number of structural elements 10.

NF PBR device 100 of the invention may further comprise means for removing accumulated oxygen at the top of the device. For example, oxygen may be released through outlets in flexible element 40, through a uni-directional valves or any other mean (not shown).

Figure 2 is a schematically front view illustration of NF PBR device 200 in accordance with another embodiment of the present invention. NF PBR device 200 is substantially similar to NF PBR device 100 illustrated in figure 1 with some changes as will be depicted hereinafter. NF PBR device 200 comprises at least a structural element 210, a flexible element 240, and an aeration system 260, all components with similar characters as the corresponding elements illustrated in figure 1. Structural element 210 may be made of a solid frame 220 and a pattern of non continuous horizontal tight wires 224 from at least two sides of structural element 210. Due to the pressure applied on flexible element 240 from both sides by structural element 210 on its outer side and by the culture liquid medium on its inner side, flexible element 240 exceeds solid frame 220 in the spacing between horizontal wires 224 to thereby create a non flat surface area with repeating curvatures 226 similar to those illustrated in figure 1 but in horizontal position instead of vertical position. Structural element 210 may be supported and/or elevated in a similar manner as structural element 10 of figure 1, to allow mechanical stability to NF PBR device 200 by any mechanical supporting component such as without limiting supporting component 203, solid grid 217, and II shaped bars 216. Additionally or alternatively, structural element 210 may be tilted according to the position of the sun along the course of the day (not shown).

NF PBR device 200 further comprises an aeration system 260 that may include at least one gas source 262, an integral air tubing 264, at least one air inlet 266, gas transporting tubing 263, and optionally, pressure regulator 265 and a system for balancing gas concentrations (not shown). Air tubing 264 illustrated in figure 2 is an integral part of flexible element 240, wherein slightly above the bottom of flexible element 240, a non-continuous horizontal heat-stamping 243 may create a tube like structure 264 with holes 246 for air discharge as bubbles 290. In such embodiment, as no tubing is inserted into flexible element 240, gas transporting tubing 263 is required to functionally connect gas source 262 with said tube like structure 264. Air inlet 266 is located below heat stamps 243. Air injection through aeration system 260 into flexible element 240 may initiate before filling flexible element 240 with liquid medium. In such scenario, the injected air will prevent liquid from penetrating below heat stamps 243.

NF PBR device 200 may further comprise a horizontal scale up system 270 represented in figure 2 by two inflatable elements 274 instead of locking bars 72 illustrated in figure 1. Said inflatable elements may be connected to gas source 262 or to an independent gas source 276 via connecting tubing 2761. Alternatively, said inflatable elements may be connected to a pump or any other means adapted to control air pressure inside inflatable elements 274. Inflatable elements 274 may be positioned in the same location of locking bars 72 of figure 1, i.e. inside structural element 210 on opposing sides of flexible element 240. When inflated, they swell up, apply pressure from both sides of flexible element 240, thereby, restricting the flow and sectioning off flexible element 240. When the desired concentration of photosynthetic organisms has been reached, inflatable elements 274 can be deflated and repositioned further down and then re-inflated upon demand. NF PBR device 200 may comprise more than one set of inflatable elements 274 that may be distributed across the entire length of the device and be inflated and deflated as necessary. Inflatable elements 274 may be filled up with gas and depleted from gas in an automated manner or manually in the same manner as scale up system 70 of figure 1.

NF PBR device 200 may further comprise a harvesting system 230, illustrated in figure 2 as two horizontal harvesting bars 232. In the embodiment illustrated in figure 2, harvesting bars 232 are positioned differently then harvesting bars 32 illustrated in figure 1, as they are located inside structural element 210, one from each side of flexible element 240, near its upper part and not near the bottom as illustrated in figure 1. Alternatively, harvesting system 230 may be positioned at the lower part of NF PBR device 200 as illustrated in figure 1. Harvesting bars 232, when pressed against one another, following floatation of a desired product, i.e. a photosynthetic microorganism or a material produced by photosynthetic organism and secreted to operating volume 246, may separate the liquid medium and the majority of the photosynthetic microorganisms or the desired product inside flexible element 240 into two uneven parts, allowing for extraction, through a harvesting draining outlet 236 of a high concentration of the desired product along with a minimum amount of liquid medium, creating an efficient harvesting process. The means to press harvesting bars 232, against one another may be any mechanical or electrical means as described in details with reference to harvesting bars 32 of figure 1.

NF PBR device 200 may further comprise one or more outlets 245 for overall draining of culture fluid along with the photosynthetic microorganisms and materials that may be located near the bottom of flexible element 240. Also shown in this figure are: rolled portion of flexible element 244 together with rolling stick 271, curvature 226, and liquid inlet 249.

NF PBR device 200 may further comprise a heat exchange unit and heat- exchange accessories for circulating heating or cooling liquid in pressurized tubing as illustrated in figure 1. In case that harvesting system 230 is positioned near the upper part of flexible element 240, as described in figure 2, the heat tubing would be inserted through the side of flexible element 240 (and not from its top, as portrayed in figure 1) lower of harvesting bars 232, to allow the sectioning of flexible element 240 as described above. NF PBR device 200 may further comprise an artificial lighting source and any other feature as described for NF PBR device 100 above.

Additional components may further be implemented in NF PBR devices of the present invention such as: external water sprayers for temperature control and maintenance, light filter for allowing only specific light wavelengths to enter the system, sensors and additional means for monitoring and regulating pH, nutrients and/or any other desired parameters.

Figure 3 is a schematic top view illustration of NF PBR device 100 of figure 1. Viewed from the top: solid frame 20, flexible element 40, supporting component 3, π shaped bar 16, solid grid 17, liquid inlet 49, curvatures 26, locking bars 72, connector 78, rolled part of flexible element 44, rolling stick 71, and operating volume 46. All features and characters of the elements and component mentioned in the above are the same as described with reference to figure 1.

Figure 4 is a schematic front view illustration of an embodiment of an aeration system 260 of NF PBR device 200 illustrated in figure 2. The embodiment illustrated herein may be also relevant to NF PBR device 100 portrayed in figure 1 and any other embodiments of NF PBR device of the present invention. In order to simplify the explanation, major elements such as structural element 10, solid bars 22 as well as other optional systems such as harvesting system 30, scale up system 70 and others, were not included in this illustration.

In the embodiment illustrated in figure 4 aeration tubing 64 is an integral part of flexible element 40, where near the bottom of flexible element 40 there is a non- continuous horizontal heat-stamping 43 connecting the two sides of flexible element 40 thereby creating a segment at the bottom of flexible element 40 which inflates when air or any other gas from gas source 62 is forced through air transporting tubing 63 below air stamps 43, to create a tube-like structure with multiple discharge holes 47, which are actually the spaces between two adjacent heat stamps 43. The shape, number and density of heat stamps 43 may vary and the holes 47 number and sizes may vary accordingly. When air is pushed through air inlet 62 into flexible element 40 air bubbles 90 are discharged to operating volume 46 at specific points where heat-stamping is missing, i.e. through holes 47. Aeration system 60 may further comprise pressure regulator 65 that is functionally adapted to allow regulation of the pressure of the gas injected into flexible element 40. Aeration system 60 is designed to create a favorable circulation for the photosynthetic organisms allowing for improved light dark cycle regime, and absorbance of air components from the culture liquid medium.

Figures 5A to 5C illustrate embodiments of harvesting bars. Figures 5Al, 5 A2, 5B 1 and 5B2, which are schematic close up cross section side view illustrations of various embodiments of harvesting bars and to figures 5Cl and 5C2, which are schematic close up side view illustrations of additional embodiment of harvesting bars in opened and closed positions in accordance with embodiments of the harvesting system of the present invention.

Figures 5Al, 5Bl and 5Cl demonstrate an example of the position of harvesting components: ridge 575B and crater 575A located one at each side of flexible element 540 in figure 5Al and harvesting bars 576 A, 576B and 576C located from both sides of flexible element 540 in figure 5Bl, and rigid frame with a slit 578A and cylindrical element 578B located one at each side of flexible element

540 in figure 5Cl, in an opened position during cultivation of photosynthetic organisms before the harvesting process occurs or after the harvesting process is completed and the harvesting bars are returned to their starting (opened) position.

Figures 5A2, 5B2 and 5C2 exemplify the sectioning off of flexible element 540 during harvesting. Harvesting components, ridge 575B and crater 575A are pushed together in figure 5A2 squeezing flexible element 540 until functionally dividing it into two parts. Harvesting bars 576A, 576B and 576C may be a mechanical bars or magnetic bars that are coupled tightly together in closed position either by mechanical or magnetic forces. Alternatively, bars 576A, 576B and 576C are inflatable bars that are filled with air in closed position proximity to one another and to the flexible element 540 in order to apply pressure on flexible element 540, thereby section off flexible element 540 into two uneven parts. In figure 5C2, harvesting bar 578B is attached to or even inserted into the slit of rigid frame 578A thus, applying pressure on flexible element 540 until functionally dividing it into two separated parts. During harvesting one part of divided flexible element 540 contains small amount of liquid medium and high concentration of desired product and is later on drained, while the other part of divided flexible element 540 is maintained in the system for further cultivation. After harvesting process is completed, the harvesting components are repositioned in their original locations as demonstrated in figures 5Al and 5Bl and 5Cl to allow for further cultivation. This process may be repeated numerous times as needed. The embodiments of harvesting bars illustrated in figures 5 may be used as locking bars of the scale up system of the present invention when they are positioned in a vertical position instead of horizontal position.

Figure 6 illustrates a schematic side view of a scale up system slider in accordance with embodiment of the present invention. The term "slider" as used herein refers to a mechanism for sectioning off segments of flexible element 640 that can slide or move across the length of flexible element 640. The slider may be built out of any rigid frame 679B such as plastic, wood, steel or titanium with a slit down its center. Flexible element 640 is passed through the slit in the rigid material. Another rigid cylindrical element 579 A which is free to rotate sits between flexible element 640 and rigid frame 579 A, creating a tight seal so that the fluid inside flexible element 640 is held in place. As this slider moves across the length of NF

PBR device 100 by any means such as electric motor, pulley, etc., (not shown) rigid cylindrical element 579A rotates to allow for a bigger part of flexible element 640 that was unrolled from rolled part of flexible element 644 rolled on rolling stick 671, to be filled with liquid medium through a liquid inlet (not shown) to thereby increase operating volume 646 as needed. This process may be repeated numerous times as needed or until maximum capacity of the operational volume is met. NF PBR device of the present invention and all embodiments described herein may be used for the cultivation of any photosynthetic organisms (e.g. marine or fresh water microalgae and macroalgae, cyanobacteria, etc.). A plurality of the NF PBR devices may be arranged in various arrays (e.g. parallel rows, grid, serpentine, etc.) and are capable to provide any required scale of cultivation.

It should be clear that the description of the embodiments and attached figures set forth in this specification serves only for a better understanding of the invention, without limiting the scope. It should also be clear that a person skilled in the art, after reading the present specification could make adjustments or amendments to the attached figures and above described embodiments that would still be covered by the present invention.

Claims

1. A Non-flat photobioreactor device comprising: a structural element composed of at least a solid frame and a pattern of non continuous repeating bars in either a vertical or horizontal position said structural element is adapted for supporting a flexible element; and a flexible element adapted for holding liquid medium for photosynthetic organism cultivation;

Wherein, upon filling said flexible element with liquid medium, said flexible element exceeds said non continuous bars of structural element to thereby create a non flat surface area with repeating curvature. 2. A Non-flat photobioreactor device according to claim 1, further comprising a real time horizontal scale up system.

3. A Non-flat photobioreactor device according to claim 2, wherein said real time horizontal scale up system comprising at least one of the following components: mechanical bars, magnetic bars, electromagnetic bars, solid plate and bar, inflatable elements, a ring like valve, and a slider.

4. A Non-flat photobioreactor device according to claim 3, wherein said components are adapted to allow sealing of said flexible element by applying pressure on said flexible element to thereby restrict said liquid medium for cultivation to a defined section of said flexible element. 5. A Non-flat photobioreactor device according to claim 3, wherein said components are either added, subtracted or re-positioned along said flexible element in a gradual and controllable manner to allow either a larger or a smaller portion of said flexible element to be filled with liquid medium, thereby increasing or decreasing an operating volume as needed. 6. A Non-flat photobioreactor device according to claim 5, wherein said operating volume comprises at least a liquid medium for cultivation and photosynthetic organisms.

7. A Non-flat photobioreactor device according to claim 1, further comprising a harvesting system adapted to allow extraction of a high concentration of at least one desired product along with a minimum amount of said liquid medium.

8. A Non-flat photobioreactor device according to claim 7, wherein extraction of a high concentration of at least one product along with a minimum amount of said liquid medium is achieved by dividing said flexible element into at least two uneven parts.

9. A Non-flat photobioreactor device according to claim 8, wherein dividing said flexible element into at least two uneven parts is conducted either after precipitation or floatation of said desired product.

10. A Non-flat photobioreactor device according to claim 7, wherein dividing said flexible element into at least two uneven parts is conducted by at least one of the following components: mechanical bars, magnetic bars, electromagnetic bars, solid plate and bar, and inflatable elements.

11. A Non-flat photobioreactor device according to claim 10, wherein said components are adapted to be positioned horizontally from both outer sides of said flexible element, either near the top portion or near the bottom, and to apply pressure towards the center of said flexible element to thereby allow division of said flexible element into at least two uneven parts.

12. A Non-flat photobioreactor device according to claim 7, wherein said desired product is either one of a photosynthetic organism cultivated in said liquid medium or a material produced by a photosynthetic organism cultivated in said liquid medium, or a mixture thereof. 13. A Non-flat photobioreactor device according to claim 7, wherein extraction of a high concentration of at least one product along with a minimum amount of said liquid medium is achieved by collecting said product that naturally floats to upper part of said liquid medium.

14. A Non-flat photobioreactor device according to claim 7, wherein said harvesting system allow efficient extraction of said product by only removing a small portion of the liquid medium compared to the operating volume that contains a high concentration of said product.

15. A Non-flat photobioreactor device according to claim 1, further comprising an aeration system, said aeration system comprising at least a gas source, a gas inlet, and an aeration tubing.

16. A Non-flat photobioreactor device according to claim 15, wherein said aeration tubing is either an integral part of said flexible element or an independent part separated thereof that is inserted into said flexible element.

17. A Non-flat photobioreactor device according to claim 16, wherein said integral aeration tubing is created by horizontal non continuous heat stamping near the bottom of said flexible element.

18. A Non-flat photobioreactor device according to claim 16, wherein aeration is achieved by injecting air through an air inlet bellow said heat stamping to functionally create a tube like structure, wherein said injected air goes up to the liquid medium through points where heat stamps are missing. 19. A Non-flat photobioreactor device according to claim 15, wherein said aeration system is further adapted to provide temperature regulation of said liquid medium for cultivation by injecting heated or chilled air. 20. A Non- flat photobioreactor device according to claim 1, further comprising a heat exchange unit. 2 LA Non-flat photobioreactor device according to claim 1, further comprising an artificial lighting source inside or outside said flexible element to said liquid medium.

22.A Non- flat photobioreactor device according to claim 1, further comprising supporting components adapted to mechanically stabilize said structural element upon filling said flexible element with liquid medium.

23.A Non-flat photobioreactor device according to claim 1, further comprising a tilting mechanism. 24. A Non-flat photobioreactor device according to claim 1, wherein said flexible element is either translucent or transparent. 25.A Non-flat photobioreactor device according to claim 1, wherein said photosynthetic organisms are selected from the group consisting: marine microalgae, marine macroalgae, fresh water microalgae, fresh water macroalgae, and cyanobactiria.

26. A Non-flat photobioreactor device according to claims 1 to 25, wherein either one of said scale up system, harvesting system, aeration system, tilting system, artificial lighting system and heat exchange unit is operated manually or automatically, or a mixture thereof.

27. A photobioreactor device for photosynthetic organisms cultivation comprising: a) a non flat structure adapted to increase surface area to volume ratio; b) a real time horizontal scale up system adapted to allow increasing or decreasing of an operating volume of a culture liquid medium as needed; and c) a harvesting system adapted to allow extraction of a high concentration of at least one desired product along with a minimum amount of said culture liquid medium.

28.A photobioreactor device according to claim 27 wherein said non flat structure comprises: a) a structural element composed of at least a solid frame and a pattern of non continuous repeating bars in either a vertical or horizontal position said structural element is adapted for supporting a flexible element; and b) a flexible element adapted for holding a liquid medium for photosynthetic organisms cultivation;

Wherein, upon filling said flexible element with said liquid medium it exceed said non continuous bars of structural element to thereby create a non flat surface area with repeating curvature.

29. A photobioreactor device according to claim 28, wherein said flexible element is either transparent or translucent.

30. A photobioreactor device according to claim 27, wherein said real time horizontal scale up system comprises at least one of the following components: mechanical bars, magnetic bars, electromagnetic bars, solid plate and bar, inflatable elements, a ring like valve, and a slider.

31. A photobioreactor device according to claim 30, wherein said components are adapted to allow sealing of said flexible element by applying pressure on said flexible element to thereby restrict said liquid medium for photosynthetic organisms cultivation to a defined section of said flexible element.

32.A photobioreactor device according to claim 30, wherein said components are either added, subtracted or re-positioned along said flexible element in a gradual and controllable manner to allow either a larger or a smaller portion of said flexible element to be filled with liquid medium, thereby increasing or decreasing an operating volume as needed.

33.A photobioreactor device according to claim 27, wherein said harvesting system allows extraction of a high concentration of at least one product along with a minimum amount of said liquid medium by dividing said flexible element into at least two uneven parts.

34. A photobioreactor device according to claim 33, wherein dividing said flexible element into at least two uneven parts is conducted either after precipitation or floatation of said desired product.

35.A photobioreactor device according to claim 33, wherein dividing said flexible element into at least two uneven parts is conducted by at least one of the following components: mechanical bars, magnetic bars, electromagnetic bars, solid plate and bar, and inflatable elements.

36.A photobioreactor device according to claim 35, wherein said components are adapted to be positioned horizontally from both outer sides of said flexible element, either near the top portion or near the bottom, and to apply pressure towards the center of said flexible element to thereby allow dividing of said flexible element into at least two uneven parts.

37. A photobioreactor device according to claim 27, wherein said desired product is either one of a photosynthetic organism cultivated in said liquid medium or a material produced by a photosynthetic organism cultivated in said liquid medium, or a mixture thereof.

38.A photobioreactor device according to claim 27, further comprising at least one of: an aeration system, artificial lighting system, tilting system, supporting components adapted for mechanically stabilizing said structural element, and a heat exchange unit.

39. A photobioreactor device according to claim 38, wherein either one of said scale up system, harvesting system, aeration system, artificial lighting system, tilting system and heat exchange unit is operated manually or automatically, or a mixture thereof.

40. A photobioreactor device according to claim 27, wherein said photosynthetic organisms are selected from the group consisting: marine microalgae, marine macroalgae, fresh water microalgae, fresh water macroalgae, and cyanobactiria.

41. A real time horizontal scale up system adapted to allow increasing or decreasing of an operating volume of a liquid medium for photosynthetic organisms cultivation as needed in a photobioreactor device comprising a flexible chamber for holding said operating volume of liquid medium.

42. A real time horizontal scale up system according to claim 41, wherein said scale up system comprises at least one of the following components: mechanical bars, magnetic bars, electromagnetic bars, solid plate and bar, inflatable elements, a ring like valve, and a slider. 43.A real time horizontal scale up system according to claim 42, wherein said components are adapted to allow sealing of said flexible chamber by applying pressure on said flexible chamber to thereby restrict said liquid medium for photosynthetic organisms cultivation to a defined section of said flexible chamber.

44.A real time horizontal scale up system according to claim 42, wherein said components are either added, subtracted or re-positioned along said flexible chamber in a gradual and controllable manner to allow either a larger or a smaller portion of said flexible chamber to be filled with liquid medium, thereby increasing or decreasing said operating volume as needed.

45. A harvesting system adapted to allow extraction of a high concentration of at least one desired product along with a minimum amount of a culture liquid medium in a photobioreactor device comprising a flexible chamber for holding said culture liquid medium.

46. A harvesting system according to claim 45, wherein said harvesting system allows extraction of a high concentration of at least one desired product along with a minimum amount of said culture liquid medium by dividing said flexible chamber into at least two uneven parts.

47.A harvesting system according to claim 46, wherein dividing said flexible chamber into at least two uneven parts is conducted either after precipitation or floatation of said desired product. 48.A harvesting system according to claim 46, wherein dividing said flexible chamber into at least two uneven parts is conducted by at least one of the following components: mechanical bars, magnetic bars, electromagnetic bars, solid plate and bar, and inflatable elements.

49. A harvesting system according to claim 48, wherein said components are adapted to be positioned horizontally from both outer sides of said flexible chamber, either near the top portion or near the bottom, and to apply pressure towards the center of said flexible chamber to thereby allow dividing of said flexible chamber into at least two uneven parts.

50. A harvesting system according to claim 45, wherein said desired product is either one of a photosynthetic organism cultivated in said liquid medium or a material produced by a photosynthetic organism cultivated in said liquid medium, or a mixture thereof.

51. A harvesting system according to claim 50, wherein said photosynthetic organism is selected from the group consisting: marine microalgae, marine macroalgae, fresh water microalgae, fresh water macroalgae, and cyanobactiria.