CA2748225A1 - Vertical pond photo bioreactor with low-cost thermal control system - Google Patents
Vertical pond photo bioreactor with low-cost thermal control system Download PDFInfo
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- C12M21/00—Bioreactors or fermenters specially adapted for specific uses
- C12M21/02—Photobioreactors
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- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
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Abstract
A vertical pond photobioreactor created by bending an elongate extruded panel in a serpentine shape. The panel inner surface is covered with fins over which is laid a transparent disposable plastic sleeve inserted inside and along the panel length for containing the algal solution. Inner fins act as low-cost air or water jacket for controlling the algal solution temperature. Replacing the low-cost disposable sleeve eliminates the need for maintenance or clean-up. Sleeves may also incorporate strips of membrane to accelerate dewatering. The system integrates an LED-based lighting system.
Description
Vertical Pond Photo Bioreactor with Low-cost Thermal Control System FIELD OF INVENTION
The disclosure herein generally relates to vertical photobioreactor apparatus for culturing microalgae and other light capturing organisms' using a photosynthetic process. More particularly, the invention relates to a vertical pond photobioreactor able to farm large volumes of culture on a small surface area and integrate into the reactor a conditioning system, a fast maintenance system, a light penetrating system at daytime and an LED lighting system at night time.
The growth of phototropic organisms in a photobioreactor present multiple design challenges; a first challenge is to provide a photobioreactor that presents sufficient light intensity to the organisms for maximum growth and as uniformly as possible throughout the support media (usually nutrient rich water), and this both at daytime and at night time; a second challenge is to reduce maintenance and cleaning costs of the system; a third challenge is to control the temperature of the culture in a cost-effective manner; and finally but not the least, to provide a reactor that can be produced using a low-cost manufacturing method.
BACKGROUND
Burning of fossil fuels is thought to have resulted in elevated atmospheric carbon dioxide (CO2) concentrations. The levels of carbon dioxide are expected to double in as little as 60 years based on changes in land use and continued burning of fossil fuels. The increase in carbon dioxide concentrations as well as other greenhouse gases is thought to keep heat within the atmosphere, leading to higher global temperatures. Sequestration--the long term capture and storage of carbon dioxide-has been long thought of as a way to mitigate this problem.
Given however, that light and carbon dioxide make up most of what is consumed, direct conversion of ambient carbon dioxide to valuable products, such as fuels, chemicals, drugs, and their precursors, represents an alternative and improved means to reduce the effects of carbon dioxide while maintaining the core industrial and commercial products our modern society demands.
.One of the primary limitations of using algae as a method of carbon dioxide sequestration or conversion to products has been the development of efficient and cost-effective growth systems. Open algal ponds up to 4 km2 have been researched, which, while requiring low capital expenditures, ultimately have low productivity as these systems are also subject to a number of problems.
Intrinsic to being an open system, the cultured organisms are exposed to a number of exogenous organisms which may be symbiotic, competitive, or pathogenic. Symbiotic organisms can change the culture organisms merely by exposing them to a different set of conditions. Opportunistic species may compete with the desired organism for space, nutrients, etc. Additionally, pathogenic invaders may feed on or kill the desired organism. In addition to these complicating factors, open systems are difficult to insulate from environmental changes including temperature, turbidity, pH, salinity, and exposure to the sun.
These difficulties point to the need to develop a closed, controllable system for the growth of algae and similar organisms.
Not surprisingly, a number of closed photobioreactors have been developed.
Typically, these are cylindrical or tubular (i.e., U.S. Pat. No. 5,958,761, US
Patent application No. 2007/0048859). These bioreactors often require mixing devices, increasing cost, and are prone to accumulating oxygen (O2), which inhibits algal growth.
As disclosed in WO 2007/011343, many conventional photobioreactors comprise cylindrical algal photobioreactors that can be categorized as either "bubble columns" or "air lift reactors." Vertical photobioreactors, which operate as "bubble columns" are large diameter columns with algal suspensions wherein gas is bubbled in from the bottom. Using bubbling as a means of mixing in large-diameter columns is thought to be inefficient, providing for lower net productivity as certain elements of the culture remain photo-poor and as large bubbles of gas do not deliver necessary precursors. An alternative vertical reactor is the air-lift bioreactor, where two concentric tubular containers are used with air bubbled in the bottom of the inner tube, which is opaque. The pressure causes upward flow in the inner tube and downward in the outer portion, which is of translucent make.
These reactors have better mass transfer coefficients and algal productivity than other reactors, though controlling the flow remains a difficulty.
Efficient mixing and gas distribution are key issues in developing closed bioreactors and to date, such efficient bioreactors do not exist.
Subitec GmbH, a German company (as disclosed on their website (http://en.subitec.com/microalgae-technology/patents.html ) developed Flat Panel Airlift photobioreactors with multiple advantages as disclosed in two families of patents EP 1169 428 131 - photobioreactors with improved light input and EP 1 326959 131 - Bioreactor for the cultivation of microorganisms, and processes for manufacturing the same. However, these flat panel reactors contain limited volumes of algal solutions, have no integrated heating or cooling system and are difficult to clean.
Tubular bioreactors, when oriented horizontally, typically require additional energy to provide mixing (e.g., pumps), thus adding significant capital and operational expense. In this orientation, the O2 produced by photosynthesis can readily become trapped in the system, thus causing a significant reduction in algal proliferation. Other known photobioreactors are oriented vertically and agitated pneumatically. Many such photobioreactors operate as "bubble columns."
All closed bioreactors require light, either from the sun or artificially derived (U.S.
Pat. No. 6,083,740). Solar penetration is typically enabled through translucent tubing, which, with thinner diameter, enables more thorough saturation of the algae. Some known photobioreactor designs rely on artificial lighting, e.g.
fluorescent lamps, (such as described by Kodo et al. in U.S. Pat. No.
6,083,740), and can otherwise be provided by any light source existing today.
Photobioreactors that do not utilize solar energy but instead rely solely on artificial light sources can require enormous energy input, increasing cost, and rendering these systems, as stand-alone approaches, impractical. Using natural solar light requires a low cost means to allow for proper penetration of the culture while maintaining the culture at a temperature that is appropriate.
Many different photobioreactor configurations have been described in the literature including flat panels, bubble columns, tubular reactors and a variety of annular designs aimed at improving the surface area to volume ratio to maximize conversion of sunlight and CO2 to biomass or other products such as algal oil. These reactors have distinct advantages compared to open raceway with respect to controlling temperature, pH, nutrient and limiting contamination (see Pulz, O. "Photobioreactors: Production systems for phototrophic microorganisms", Appl. Microbiol. Biotechnol (2001) 57:287-293). Key limitations to their adoption have been the cost vs. benefit as it relates to the product being produced. Whereas valuable products such as carotenoids have been produced in photobioreactors the production of biomass for fuels could not be economically justified to date.
The art as it relates to enclosed photobioreactors achieve temperature control in a variety of ways including external and internal heat exchangers, spraying of cooling water directly on the surface, use of cooled or heater sparge gas as well as submerging the reactor directly in large pond of water that is separately temperature controlled (see Molina Grima, E. et al "Photobioreactors: light regime, mass transfer, and scale-up", J. of Biotechnology (1999) 70:231-247;
Hu, Q. et al "A flat inclined photobioreactor for outdoor mass cultivation of photoautotrophs" Biotechnology and Bioengineering (1996) 51:51-60 and Hu, Q.
WO 2007/098150 A2 "Photobioreactor and uses therefor"). Currently, a cost-effective thermal regulation system that can be implemented in large scale does not exist.
What is needed, therefore, is a low-cost efficient integrated photobioreactor system that is scalable, is virtually maintenance-free, presents good light exposure to microorganism, integrates its own temperature control and may be produced using a low-cost manufacturing method such as extrusion.
SUMMARY
In various embodiments, a vertical serpentine-shape pond photobioreactor is described which can provide sufficient productivity for growing micro-organisms for commercial application. The disclosed apparatus works in combination with a translucent disposable sleeve inserted into the apparatus chamber which contains the microalgae culture. The method of temperature control for any photobioreactor using the principle taught by this invention is provided by incorporating on the interior surface of the bioreactor fins that create a space over which is resting the plastic sleeve. By displacing a fluid in-between these fins such as air or water, an air or water jacket is created for conditioning the content of the sleeve. Such photobioreactor apparatus and methods are optimized for light capture and require virtually no maintenance. Using a low-cost extrusion process keeps costs down. The serpentine-shape of the bioreactor is provided by bending a rectangular-shape extruded profile to form the chamber of the bioreactor. This bending method, also called BendTrusionTM (BendTrusion is a Trade Mark of Soheyl Mottahedeh) was developed and disclosed in another invention of the same inventor. Said method ensures that costs remain low so that replication of the apparatus is scalable and that the system achieves efficient growth of the culture. In various embodiments, such organisms grown in the disposable sleeve positioned in the vertical pond chamber are used in the production of biomass and chemical intermediates as well as a means to biologically produce end products such as fuels, chemicals and pharmaceutical agents.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective cross-section view of a part of the panel that will be extruded and bent to form a serpentine-shape or a helical -shape vertical pond photobioreactor.
FIG. 2 depicts the view of the panel of FIG. 1 containing a first outer translucent plastic sleeve and a second inner also translucent plastic sleeve that incorporates strips of membrane.
FIG. 3 depicts a perspective view of a part of a tubular shape photobioreactor having some shorter and some longer inner fins with four LED cord sections.
FIG. 4 depicts a cross-section view of FIG. 4 with a plastic sleeve inside for containing an algal solution FIG. 5 depicts a perspective view of the panel of FIG. 1 with a translucent plastic sleeve substantially inserted in it but for a small portion hanging outside a the panel side opening.
FIG. 6 depicts a perspective view of the multi-layered sleeve of FIG. 2 FIG. 7 is an illustration of a multiple photobioreactor assemblies connected in fluid communication, each photobioreactor featuring a removable lower connector provided with two removable spargers for providing circulation of media and mixing of cultures.
FIG. 8 depicts a tubular extruded profile bended in a pyramidal shape.
FIG. 9 depicts another tubular extruded profile bended in a conical shape.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Photobioreactor Apparatus & Light Capture The invention provides an efficient, low-cost, high surface area light capturing apparatus that is scalable and easily implemented in open space such as the exemplary photobioreactor apparatus as shown in FIG. 7. Such photobioreactor apparatus is adapted to capture light through a generally horizontally-oriented elongate panel 100 shown in FIG. 1. The elongate panel 100 may take on the shape of a vertical rising serpentine as shown in FIG. 7, a helically-shaped cylinder (not shown), a helically shaped cone (FIG. 9) or pyramid (FIG. 8), or any combination of these shapes . Since different types of light capturing organisms can require different light exposure conditions for optimal growth and proliferation, additional modifications can be made to the construction of a photobioreactor apparatus to capture light according to the various embodiments.
In certain embodiments, the photobioreactor apparatus is used with natural sunlight, however, in alternative embodiments, an artificial light source such as Light Emitting Diodes (LED) 380 shown in FIGS. 3 and 4 providing light at wavelengths that is able to drive photosynthesis may be utilized instead of or in addition to natural sunlight. For example, a photobioreactor apparatus is configured to utilize sunlight during the daylight hours and artificial light in the nighttime, so as to increase the total amount of time during the course of the day in which the photobioreactor apparatus can convert light, CO2 and water to products through use of photosynthetic organisms.
The photobioreactor of the invention can be illustrated in various dimensions, shape and designs. In preferred embodiments, the photobioreactor is made of an extruded panel 100 with a generally rectangular cross-sectional profile. Panel 100 takes on the shape of a horizontally-oriented flat-panel design that is bent in various shapes. Shapes may vary from serpentine 110 to a range of helically-shaped profiles including cylindrical (not shown), conical 130 or pyramidal configurations, or a combination thereof. Panel 100 is comparable to a vertical raceway or a vertical pond. The top 112 and bottom 114 ends of panel 100 are configured so as to face respectively the top 112 and bottom 114 of other panel 100 ends. A connector 212 connects two panel ends 112 and a connector 214 connects two panel ends 114. Connectors 212 and 214 allow for continuous flow-through of culture while providing input of air, of co2 and of nutrients.
Structural support between layers of panels 100 is provided to reduce pressure on curved portions of photobioreactors.
The inside surface of panel 100 is covered with multiple fins 116 perpendicularly oriented in relation to the surface. Fins 116 play collectively the function of an air or water jacket for heating or cooling sleeve 300 and 360.
The panel 100 may be in various shapes and sizes and is generally designed to allow a desired amount of light to penetrate the channel 200. A useful feature of the photobioreactor panel 100 allows visible light spectra of wavelengths between 400-700 nm to enter sleeve 300 for optimum LED lighting of the organisms at night time while filtering out the unwanted wavelengths in the spectra.
An elongate flexible thin sleeve 300 similar to a plastic film is positioned inside panel 100 to contain an algal solution; sleeve 300 is at least partially translucent;
In another embodiment of the invention, sleeve 300 is provided with strips 310 of a translucent film being bonded side-by-side to strips of membrane 320.
Membrane 320 may be of an osmosis membrane type or of a reverse osmosis membrane type or of a micro-filter type.
Translucent strips 310 may be bonded to membrane strips 320 side-by-side lengthwise as shown in FIGS. 2 and 6 or helically (not shown).
Membrane strips 320 are configured to gradually dewater the algal solution reducing the amount of energy needed before lipid extraction is initiated.
In another embodiment of the invention, a sleeve 360 is provided by containing inside a fully translucent outer sleeve 300 a combined membrane-plastic sleeve 320.
A fluid inserted in-between the outer sleeve 300 and the combined membrane-plastic sleeve 320 is provided to affect the algal fluid. Fluidic effects on the algal fluid are intended to cause an intended reaction on or to stimulate algal growth, to condition the algal fluid by heating or cooling it, to improve extraction of lipids, to create enzymatic reactions or engender reactions of the like.
As mentioned before, temperature control of the algal solution inside sleeve may be achieved by displacing a fluid in the space between fins 116, around sleeve 300.
The disposable flexible sleeve 300, 320 and 360 may be selected from biodegradable materials. To guarantee a bacteria-free environment to the algal solution, sleeves 300, 320 and 360 may be sterilized by both UV and Gamma light before use.
Providing photobioreactor panel 100 with a disposable low-cost sleeve 300 enables to maintain and clean the system in a cost-effective manner, eliminating the need to waste excessive amount of water or of chemicals to clean the photobioreactor panel 100. Furthermore, a quick replacement of a disposable sleeve 300 and 360 extending partially or extending along the full length of an assembly of multiple photobioreactor panels 100 reduces effectively operation downtime for maintenance.
The fluid displaced or circulated in-between finsl 16 is selected from the group consisting of a gas, a liquid, a slurry containing solid particles or a combination thereof. Displacing a fluid in-between fins 116 for conditioning the algal solution may not be limited to only heating or cooling. Other types of conditioning may also be provided such as:
- Illuminating the algal solution with a fluorescent gas or a bio-luminescent or chemo luminescent liquid or gas;
- reflecting light by circulating in between fins 116 a reflective liquid such as an aluminized liquid. This may save energy by reflecting back an artificial light intended to illuminate the algal solution and reduce losses of light to the external environment.
- Shielding the algal solution against darkness or excess light may be another advantage - Filling with water space between fins 116 acts as a water lens to magnify light to provide maximum light input to the algal solution - knowing that a magnetic field promotes growth of a culture by manifolds, circulating a liquid with magnetic particles may be very beneficial - when de-magnetizing is required, circulating a liquid with the right property may be beneficial to the culture - controlling light density by circulating a colored liquid may reduce the negative effects of excess light - circulating a liquid that filters some light colors such as UV light known to inhibit organisms growth is beneficial to the culture - insulating the algal solution against cold or excess heat with for example soap bubbles has proven to be very efficient in greenhouses used in the Northern Hemisphere - shielding the algal solution against darkness against radiation is another features of the water jacket of the invention - using a solution containing some light-emitting organisms that generate light at night may reduce the amount of artificial light.
- A combination of the above features may be also be provided by circulating the right fluid in the air or water jacket of the invention.
The distance between fins 116 may be configured so that when sleeve 300 is filled with an algal solution, sleeve 300 and 360 may rest over tips of fins without having the thin plastic sleeve 300, 320 and 360 to creep into the space between fins 116. This may be achieved by selecting the right sleeve thickness, the right distancing between fins 116 and the right perimeter of the sleeve of slightly smaller dimension than the panel interior perimeter when distances between all fins 116 tips are added.
To speed up insertion and exit of sleeve 300, 320 and 360, phobioreactor panel 100 chamber of generally rectangular-shape is provided with a narrow side opening 150 positioned along the full length of the photo bioreactor panel 100. In practice, this narrow opening 150 assists in the fabrication of the extrusion die used for the extrusion of panel 100.
In an embodiment of sleeve 300, 320 and 360 wherein a photo bioreactor panel 100 is provided with a side opening 150, the width of sleeve 300, 320 and 360 may be extended so that a portion of sleeve 300, 320 and 360 may be gripped in between the upper and lower lips of side opening 150. Such an arrangement may be useful when extra sleeve material helps when sealing the space around which a perfusion needle (connected to a tube) such as for oxygen (O2) removal is inserted into sleeve 300, 320 and 360. In another instance, when inserting a right-hand and a left-hand sparger tubes (not shown) or nutrient delivery tubes into the algal culture, puncturing of the sleeve 300, 320 and 360 is required to access algal culture. Connectors 212 and 214 are configured to seal all tubes and deliver conditioning fluids without fluid leakage.
When sleeve 320 is used in the photo bioreactor 1000 as a means to dewater the algal solution, fins 116 serve as water collection channels with gravity bringing liquids down into bottom collector 212 which is provided with means to channel such restored water for recycling purposes.
A photo bioreactor bottom end 114 may be connected via a bottom connector 214 to a bottom end of another bioreactor 114; similarly two top ends 112 of two bioreactor panels 100 may be connected together via a top connector 212.
The bottom connector 212 is provided with tubes for sparging a mix of air and COsub2 and for delivery of nutrients into the algal solution. Also, this bottom connector is provided with a channel for displacing a conditioning fluid around the sleeve 300, 320 or 360 inside the photobioreator panel 100 chamber.
To minimize leaking, length of sleeve 300, 320 and 360 may extend to cover the entire length of multiple photo bioreactor pnels 100 when connected together.
However, for convenience or for quick inter-changeability of disposable sleeves 300, 320 and 360 the sleeve 300, 320 and 360 length may extend to line the inner space of one or two photo bioreactor panels 100 at a time. Also, the length necessary to line some photo bioreactor panels 100 with one type of membrane 320 and a length to line other photo bioreactor panels 100 with another membrane type may vary depending on algal solutions and algal growth level or other desired factors intended to reduce production costs of end products.
In yet another embodiment of the invention as shown in FIGS. 3 and 4, selected fins 118 are more elevated than other fins 116. This additional length for longer fins 118 causes sleeve 300, 320 or 360 to adopt the body shape of these longer fins 118 along the full length of the photo bioreactor panel-type or tubular-type 200. These longer fins 118 act as light guides that bring extra light deeper into the algal culture.
In preferred embodiments, the reactor structure has a rectangular cross-sectional profile as shown in FIGS. 1, 2, 5, 6 and 7. The reactor is preferably formed through an extrusion process inline with a thermoplastic bending machine. This bending machine, also called BendTrusionTM (BendTrusion is a Trade Mark of Soheyl Mottahedeh) has been disclosed by the same present inventor Mottahedeh in US Patent 7,841,850.
The reactor flow is typically driven with air-lift; bubbles introduced in the bottom connector 214 tend to rise on the top surface in the bell portion of upper connector 212.
The disclosure herein generally relates to vertical photobioreactor apparatus for culturing microalgae and other light capturing organisms' using a photosynthetic process. More particularly, the invention relates to a vertical pond photobioreactor able to farm large volumes of culture on a small surface area and integrate into the reactor a conditioning system, a fast maintenance system, a light penetrating system at daytime and an LED lighting system at night time.
The growth of phototropic organisms in a photobioreactor present multiple design challenges; a first challenge is to provide a photobioreactor that presents sufficient light intensity to the organisms for maximum growth and as uniformly as possible throughout the support media (usually nutrient rich water), and this both at daytime and at night time; a second challenge is to reduce maintenance and cleaning costs of the system; a third challenge is to control the temperature of the culture in a cost-effective manner; and finally but not the least, to provide a reactor that can be produced using a low-cost manufacturing method.
BACKGROUND
Burning of fossil fuels is thought to have resulted in elevated atmospheric carbon dioxide (CO2) concentrations. The levels of carbon dioxide are expected to double in as little as 60 years based on changes in land use and continued burning of fossil fuels. The increase in carbon dioxide concentrations as well as other greenhouse gases is thought to keep heat within the atmosphere, leading to higher global temperatures. Sequestration--the long term capture and storage of carbon dioxide-has been long thought of as a way to mitigate this problem.
Given however, that light and carbon dioxide make up most of what is consumed, direct conversion of ambient carbon dioxide to valuable products, such as fuels, chemicals, drugs, and their precursors, represents an alternative and improved means to reduce the effects of carbon dioxide while maintaining the core industrial and commercial products our modern society demands.
.One of the primary limitations of using algae as a method of carbon dioxide sequestration or conversion to products has been the development of efficient and cost-effective growth systems. Open algal ponds up to 4 km2 have been researched, which, while requiring low capital expenditures, ultimately have low productivity as these systems are also subject to a number of problems.
Intrinsic to being an open system, the cultured organisms are exposed to a number of exogenous organisms which may be symbiotic, competitive, or pathogenic. Symbiotic organisms can change the culture organisms merely by exposing them to a different set of conditions. Opportunistic species may compete with the desired organism for space, nutrients, etc. Additionally, pathogenic invaders may feed on or kill the desired organism. In addition to these complicating factors, open systems are difficult to insulate from environmental changes including temperature, turbidity, pH, salinity, and exposure to the sun.
These difficulties point to the need to develop a closed, controllable system for the growth of algae and similar organisms.
Not surprisingly, a number of closed photobioreactors have been developed.
Typically, these are cylindrical or tubular (i.e., U.S. Pat. No. 5,958,761, US
Patent application No. 2007/0048859). These bioreactors often require mixing devices, increasing cost, and are prone to accumulating oxygen (O2), which inhibits algal growth.
As disclosed in WO 2007/011343, many conventional photobioreactors comprise cylindrical algal photobioreactors that can be categorized as either "bubble columns" or "air lift reactors." Vertical photobioreactors, which operate as "bubble columns" are large diameter columns with algal suspensions wherein gas is bubbled in from the bottom. Using bubbling as a means of mixing in large-diameter columns is thought to be inefficient, providing for lower net productivity as certain elements of the culture remain photo-poor and as large bubbles of gas do not deliver necessary precursors. An alternative vertical reactor is the air-lift bioreactor, where two concentric tubular containers are used with air bubbled in the bottom of the inner tube, which is opaque. The pressure causes upward flow in the inner tube and downward in the outer portion, which is of translucent make.
These reactors have better mass transfer coefficients and algal productivity than other reactors, though controlling the flow remains a difficulty.
Efficient mixing and gas distribution are key issues in developing closed bioreactors and to date, such efficient bioreactors do not exist.
Subitec GmbH, a German company (as disclosed on their website (http://en.subitec.com/microalgae-technology/patents.html ) developed Flat Panel Airlift photobioreactors with multiple advantages as disclosed in two families of patents EP 1169 428 131 - photobioreactors with improved light input and EP 1 326959 131 - Bioreactor for the cultivation of microorganisms, and processes for manufacturing the same. However, these flat panel reactors contain limited volumes of algal solutions, have no integrated heating or cooling system and are difficult to clean.
Tubular bioreactors, when oriented horizontally, typically require additional energy to provide mixing (e.g., pumps), thus adding significant capital and operational expense. In this orientation, the O2 produced by photosynthesis can readily become trapped in the system, thus causing a significant reduction in algal proliferation. Other known photobioreactors are oriented vertically and agitated pneumatically. Many such photobioreactors operate as "bubble columns."
All closed bioreactors require light, either from the sun or artificially derived (U.S.
Pat. No. 6,083,740). Solar penetration is typically enabled through translucent tubing, which, with thinner diameter, enables more thorough saturation of the algae. Some known photobioreactor designs rely on artificial lighting, e.g.
fluorescent lamps, (such as described by Kodo et al. in U.S. Pat. No.
6,083,740), and can otherwise be provided by any light source existing today.
Photobioreactors that do not utilize solar energy but instead rely solely on artificial light sources can require enormous energy input, increasing cost, and rendering these systems, as stand-alone approaches, impractical. Using natural solar light requires a low cost means to allow for proper penetration of the culture while maintaining the culture at a temperature that is appropriate.
Many different photobioreactor configurations have been described in the literature including flat panels, bubble columns, tubular reactors and a variety of annular designs aimed at improving the surface area to volume ratio to maximize conversion of sunlight and CO2 to biomass or other products such as algal oil. These reactors have distinct advantages compared to open raceway with respect to controlling temperature, pH, nutrient and limiting contamination (see Pulz, O. "Photobioreactors: Production systems for phototrophic microorganisms", Appl. Microbiol. Biotechnol (2001) 57:287-293). Key limitations to their adoption have been the cost vs. benefit as it relates to the product being produced. Whereas valuable products such as carotenoids have been produced in photobioreactors the production of biomass for fuels could not be economically justified to date.
The art as it relates to enclosed photobioreactors achieve temperature control in a variety of ways including external and internal heat exchangers, spraying of cooling water directly on the surface, use of cooled or heater sparge gas as well as submerging the reactor directly in large pond of water that is separately temperature controlled (see Molina Grima, E. et al "Photobioreactors: light regime, mass transfer, and scale-up", J. of Biotechnology (1999) 70:231-247;
Hu, Q. et al "A flat inclined photobioreactor for outdoor mass cultivation of photoautotrophs" Biotechnology and Bioengineering (1996) 51:51-60 and Hu, Q.
WO 2007/098150 A2 "Photobioreactor and uses therefor"). Currently, a cost-effective thermal regulation system that can be implemented in large scale does not exist.
What is needed, therefore, is a low-cost efficient integrated photobioreactor system that is scalable, is virtually maintenance-free, presents good light exposure to microorganism, integrates its own temperature control and may be produced using a low-cost manufacturing method such as extrusion.
SUMMARY
In various embodiments, a vertical serpentine-shape pond photobioreactor is described which can provide sufficient productivity for growing micro-organisms for commercial application. The disclosed apparatus works in combination with a translucent disposable sleeve inserted into the apparatus chamber which contains the microalgae culture. The method of temperature control for any photobioreactor using the principle taught by this invention is provided by incorporating on the interior surface of the bioreactor fins that create a space over which is resting the plastic sleeve. By displacing a fluid in-between these fins such as air or water, an air or water jacket is created for conditioning the content of the sleeve. Such photobioreactor apparatus and methods are optimized for light capture and require virtually no maintenance. Using a low-cost extrusion process keeps costs down. The serpentine-shape of the bioreactor is provided by bending a rectangular-shape extruded profile to form the chamber of the bioreactor. This bending method, also called BendTrusionTM (BendTrusion is a Trade Mark of Soheyl Mottahedeh) was developed and disclosed in another invention of the same inventor. Said method ensures that costs remain low so that replication of the apparatus is scalable and that the system achieves efficient growth of the culture. In various embodiments, such organisms grown in the disposable sleeve positioned in the vertical pond chamber are used in the production of biomass and chemical intermediates as well as a means to biologically produce end products such as fuels, chemicals and pharmaceutical agents.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective cross-section view of a part of the panel that will be extruded and bent to form a serpentine-shape or a helical -shape vertical pond photobioreactor.
FIG. 2 depicts the view of the panel of FIG. 1 containing a first outer translucent plastic sleeve and a second inner also translucent plastic sleeve that incorporates strips of membrane.
FIG. 3 depicts a perspective view of a part of a tubular shape photobioreactor having some shorter and some longer inner fins with four LED cord sections.
FIG. 4 depicts a cross-section view of FIG. 4 with a plastic sleeve inside for containing an algal solution FIG. 5 depicts a perspective view of the panel of FIG. 1 with a translucent plastic sleeve substantially inserted in it but for a small portion hanging outside a the panel side opening.
FIG. 6 depicts a perspective view of the multi-layered sleeve of FIG. 2 FIG. 7 is an illustration of a multiple photobioreactor assemblies connected in fluid communication, each photobioreactor featuring a removable lower connector provided with two removable spargers for providing circulation of media and mixing of cultures.
FIG. 8 depicts a tubular extruded profile bended in a pyramidal shape.
FIG. 9 depicts another tubular extruded profile bended in a conical shape.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Photobioreactor Apparatus & Light Capture The invention provides an efficient, low-cost, high surface area light capturing apparatus that is scalable and easily implemented in open space such as the exemplary photobioreactor apparatus as shown in FIG. 7. Such photobioreactor apparatus is adapted to capture light through a generally horizontally-oriented elongate panel 100 shown in FIG. 1. The elongate panel 100 may take on the shape of a vertical rising serpentine as shown in FIG. 7, a helically-shaped cylinder (not shown), a helically shaped cone (FIG. 9) or pyramid (FIG. 8), or any combination of these shapes . Since different types of light capturing organisms can require different light exposure conditions for optimal growth and proliferation, additional modifications can be made to the construction of a photobioreactor apparatus to capture light according to the various embodiments.
In certain embodiments, the photobioreactor apparatus is used with natural sunlight, however, in alternative embodiments, an artificial light source such as Light Emitting Diodes (LED) 380 shown in FIGS. 3 and 4 providing light at wavelengths that is able to drive photosynthesis may be utilized instead of or in addition to natural sunlight. For example, a photobioreactor apparatus is configured to utilize sunlight during the daylight hours and artificial light in the nighttime, so as to increase the total amount of time during the course of the day in which the photobioreactor apparatus can convert light, CO2 and water to products through use of photosynthetic organisms.
The photobioreactor of the invention can be illustrated in various dimensions, shape and designs. In preferred embodiments, the photobioreactor is made of an extruded panel 100 with a generally rectangular cross-sectional profile. Panel 100 takes on the shape of a horizontally-oriented flat-panel design that is bent in various shapes. Shapes may vary from serpentine 110 to a range of helically-shaped profiles including cylindrical (not shown), conical 130 or pyramidal configurations, or a combination thereof. Panel 100 is comparable to a vertical raceway or a vertical pond. The top 112 and bottom 114 ends of panel 100 are configured so as to face respectively the top 112 and bottom 114 of other panel 100 ends. A connector 212 connects two panel ends 112 and a connector 214 connects two panel ends 114. Connectors 212 and 214 allow for continuous flow-through of culture while providing input of air, of co2 and of nutrients.
Structural support between layers of panels 100 is provided to reduce pressure on curved portions of photobioreactors.
The inside surface of panel 100 is covered with multiple fins 116 perpendicularly oriented in relation to the surface. Fins 116 play collectively the function of an air or water jacket for heating or cooling sleeve 300 and 360.
The panel 100 may be in various shapes and sizes and is generally designed to allow a desired amount of light to penetrate the channel 200. A useful feature of the photobioreactor panel 100 allows visible light spectra of wavelengths between 400-700 nm to enter sleeve 300 for optimum LED lighting of the organisms at night time while filtering out the unwanted wavelengths in the spectra.
An elongate flexible thin sleeve 300 similar to a plastic film is positioned inside panel 100 to contain an algal solution; sleeve 300 is at least partially translucent;
In another embodiment of the invention, sleeve 300 is provided with strips 310 of a translucent film being bonded side-by-side to strips of membrane 320.
Membrane 320 may be of an osmosis membrane type or of a reverse osmosis membrane type or of a micro-filter type.
Translucent strips 310 may be bonded to membrane strips 320 side-by-side lengthwise as shown in FIGS. 2 and 6 or helically (not shown).
Membrane strips 320 are configured to gradually dewater the algal solution reducing the amount of energy needed before lipid extraction is initiated.
In another embodiment of the invention, a sleeve 360 is provided by containing inside a fully translucent outer sleeve 300 a combined membrane-plastic sleeve 320.
A fluid inserted in-between the outer sleeve 300 and the combined membrane-plastic sleeve 320 is provided to affect the algal fluid. Fluidic effects on the algal fluid are intended to cause an intended reaction on or to stimulate algal growth, to condition the algal fluid by heating or cooling it, to improve extraction of lipids, to create enzymatic reactions or engender reactions of the like.
As mentioned before, temperature control of the algal solution inside sleeve may be achieved by displacing a fluid in the space between fins 116, around sleeve 300.
The disposable flexible sleeve 300, 320 and 360 may be selected from biodegradable materials. To guarantee a bacteria-free environment to the algal solution, sleeves 300, 320 and 360 may be sterilized by both UV and Gamma light before use.
Providing photobioreactor panel 100 with a disposable low-cost sleeve 300 enables to maintain and clean the system in a cost-effective manner, eliminating the need to waste excessive amount of water or of chemicals to clean the photobioreactor panel 100. Furthermore, a quick replacement of a disposable sleeve 300 and 360 extending partially or extending along the full length of an assembly of multiple photobioreactor panels 100 reduces effectively operation downtime for maintenance.
The fluid displaced or circulated in-between finsl 16 is selected from the group consisting of a gas, a liquid, a slurry containing solid particles or a combination thereof. Displacing a fluid in-between fins 116 for conditioning the algal solution may not be limited to only heating or cooling. Other types of conditioning may also be provided such as:
- Illuminating the algal solution with a fluorescent gas or a bio-luminescent or chemo luminescent liquid or gas;
- reflecting light by circulating in between fins 116 a reflective liquid such as an aluminized liquid. This may save energy by reflecting back an artificial light intended to illuminate the algal solution and reduce losses of light to the external environment.
- Shielding the algal solution against darkness or excess light may be another advantage - Filling with water space between fins 116 acts as a water lens to magnify light to provide maximum light input to the algal solution - knowing that a magnetic field promotes growth of a culture by manifolds, circulating a liquid with magnetic particles may be very beneficial - when de-magnetizing is required, circulating a liquid with the right property may be beneficial to the culture - controlling light density by circulating a colored liquid may reduce the negative effects of excess light - circulating a liquid that filters some light colors such as UV light known to inhibit organisms growth is beneficial to the culture - insulating the algal solution against cold or excess heat with for example soap bubbles has proven to be very efficient in greenhouses used in the Northern Hemisphere - shielding the algal solution against darkness against radiation is another features of the water jacket of the invention - using a solution containing some light-emitting organisms that generate light at night may reduce the amount of artificial light.
- A combination of the above features may be also be provided by circulating the right fluid in the air or water jacket of the invention.
The distance between fins 116 may be configured so that when sleeve 300 is filled with an algal solution, sleeve 300 and 360 may rest over tips of fins without having the thin plastic sleeve 300, 320 and 360 to creep into the space between fins 116. This may be achieved by selecting the right sleeve thickness, the right distancing between fins 116 and the right perimeter of the sleeve of slightly smaller dimension than the panel interior perimeter when distances between all fins 116 tips are added.
To speed up insertion and exit of sleeve 300, 320 and 360, phobioreactor panel 100 chamber of generally rectangular-shape is provided with a narrow side opening 150 positioned along the full length of the photo bioreactor panel 100. In practice, this narrow opening 150 assists in the fabrication of the extrusion die used for the extrusion of panel 100.
In an embodiment of sleeve 300, 320 and 360 wherein a photo bioreactor panel 100 is provided with a side opening 150, the width of sleeve 300, 320 and 360 may be extended so that a portion of sleeve 300, 320 and 360 may be gripped in between the upper and lower lips of side opening 150. Such an arrangement may be useful when extra sleeve material helps when sealing the space around which a perfusion needle (connected to a tube) such as for oxygen (O2) removal is inserted into sleeve 300, 320 and 360. In another instance, when inserting a right-hand and a left-hand sparger tubes (not shown) or nutrient delivery tubes into the algal culture, puncturing of the sleeve 300, 320 and 360 is required to access algal culture. Connectors 212 and 214 are configured to seal all tubes and deliver conditioning fluids without fluid leakage.
When sleeve 320 is used in the photo bioreactor 1000 as a means to dewater the algal solution, fins 116 serve as water collection channels with gravity bringing liquids down into bottom collector 212 which is provided with means to channel such restored water for recycling purposes.
A photo bioreactor bottom end 114 may be connected via a bottom connector 214 to a bottom end of another bioreactor 114; similarly two top ends 112 of two bioreactor panels 100 may be connected together via a top connector 212.
The bottom connector 212 is provided with tubes for sparging a mix of air and COsub2 and for delivery of nutrients into the algal solution. Also, this bottom connector is provided with a channel for displacing a conditioning fluid around the sleeve 300, 320 or 360 inside the photobioreator panel 100 chamber.
To minimize leaking, length of sleeve 300, 320 and 360 may extend to cover the entire length of multiple photo bioreactor pnels 100 when connected together.
However, for convenience or for quick inter-changeability of disposable sleeves 300, 320 and 360 the sleeve 300, 320 and 360 length may extend to line the inner space of one or two photo bioreactor panels 100 at a time. Also, the length necessary to line some photo bioreactor panels 100 with one type of membrane 320 and a length to line other photo bioreactor panels 100 with another membrane type may vary depending on algal solutions and algal growth level or other desired factors intended to reduce production costs of end products.
In yet another embodiment of the invention as shown in FIGS. 3 and 4, selected fins 118 are more elevated than other fins 116. This additional length for longer fins 118 causes sleeve 300, 320 or 360 to adopt the body shape of these longer fins 118 along the full length of the photo bioreactor panel-type or tubular-type 200. These longer fins 118 act as light guides that bring extra light deeper into the algal culture.
In preferred embodiments, the reactor structure has a rectangular cross-sectional profile as shown in FIGS. 1, 2, 5, 6 and 7. The reactor is preferably formed through an extrusion process inline with a thermoplastic bending machine. This bending machine, also called BendTrusionTM (BendTrusion is a Trade Mark of Soheyl Mottahedeh) has been disclosed by the same present inventor Mottahedeh in US Patent 7,841,850.
The reactor flow is typically driven with air-lift; bubbles introduced in the bottom connector 214 tend to rise on the top surface in the bell portion of upper connector 212.
Claims (20)
1. A vertical pond photo bioreactor comprising:
a translucent reactor chamber of generally flat surface having a rectangular cross-sectional profile with an inner surface covered by multiple elevated fins;
a flexible thin sleeve for containing an algal solution; said sleeve being at least partially translucent; the sleeve for insertion inside said reactor chamber;
the sleeve thickness and perimeter being configured for the sleeve to rest over tips of said fins inside said bioreactor;
wherein a low-cost conditioning, such as heating or cooling of the algal solution is achieved by displacing a conditioning fluid in the space created between fins and the sleeve outer surface.
a translucent reactor chamber of generally flat surface having a rectangular cross-sectional profile with an inner surface covered by multiple elevated fins;
a flexible thin sleeve for containing an algal solution; said sleeve being at least partially translucent; the sleeve for insertion inside said reactor chamber;
the sleeve thickness and perimeter being configured for the sleeve to rest over tips of said fins inside said bioreactor;
wherein a low-cost conditioning, such as heating or cooling of the algal solution is achieved by displacing a conditioning fluid in the space created between fins and the sleeve outer surface.
2. The vertical pond photo bioreactor of claim 1, wherein the flexible sleeve is disposable and is made of a plastic biodegradable transparent material.
3. The vertical pond photo bioreactor of claim 1, wherein the flexible sleeve is made partially of strips of translucent material and partially of strips of a membrane selected from the group of membranes consisting of osmosis membrane, reverse osmosis membrane, and membranes of the like.
4. The vertical pond photo bioreactor of claim 3, wherein said strips of membrane are configured to gradually dewater the algal solution.
5. The vertical pond photo bioreactor of claim 3, wherein said combined membrane-plastic sleeve is contained inside a fully translucent outer sleeve.
6. The vertical pond photo bioreactor of claim 10, wherein a fluid contained in-between the outer sleeve and the membrane-plastic sleeve affects the algal fluid.
7. The vertical pond photo bioreactor of claim 11, wherein fluid effects on the algal fluid are selected from the group consisting of effects causing a chemical reaction such as but not limited to Hexane Solvent Method, Soxhlet extraction, enzymatic extraction, osmotic shock, pH changes, biological reaction, magnetic stimulation for algal growth, conditioning of the algal fluid, breaking of algal pouch to extract oil, enzymatic reaction, and reactions of the like.
8. The vertical pond photo bioreactor of claim 1, wherein rapid maintenance of the reactor is achievable by replacing the disposable low-cost sleeve;
thereby avoiding the need to clean the bioreactor.
thereby avoiding the need to clean the bioreactor.
9. The vertical pond photo bioreactor of claim 1, wherein said fluid is selected from the group consisting of a gas, a liquid, a slurry with solid particles or a combination thereof.
10. The vertical pond photo bioreactor of claim 1, wherein said fluid for conditioning of the algal solution is selected from the group consisting of heating, cooling, illuminating, light reflecting, magnifying, magnetizing, de-magnetizing, controlling light density, filtering light colors, filtering UV
light, insulating, shielding against darkness, shielding against excess light, shielding against radiation, generating light or a combination thereof.
light, insulating, shielding against darkness, shielding against excess light, shielding against radiation, generating light or a combination thereof.
11. The vertical pond photo bioreactor of claim 1, wherein the bioreactor cross-sectional profile is produced by an extrusion equipment.
12. The vertical pond photo bioreactor of claim 1, wherein the vertical pond bioreactor shape may be selected from the group consisting of straight vertical serpentine, helically-shaped vertical serpentine, helically-shaped cylinder, helically-shaped pyramid and a combination thereof.
13. The vertical pond photo bioreactor of claim 1, wherein the chamber rectangular profile cavity has a narrow side opening along the bioreactor for rapid insertion of the sleeve inside said cavity.
14. The vertical pond photo bioreactor of claim 13, wherein the size of the sleeve is configured for a large portion of the sleeve to be inserted sideways inside the bioreactor chamber and for a small portion to be left outside the chamber, gripped in-between the upper and lower lips of the narrow side opening along the bioreactor.
15. The vertical pond photo bioreactor of claims 1 and 3, wherein the length of the sleeve is selected from the group consisting of a length to line the inner space of one bioreactor at a time, a length to line multiple bioreactors together, a length to line some bioreactors with one type of membrane and a length to line others with other membrane type, and a combination thereof.
16. The vertical pond photo bioreactor of claim 1, wherein a bottom end of the bioreactor may be connected via a bottom connector to a bottom end of another bioreactor; similarly two top ends of two bioreactors may be connected together via a top connector.
17. The vertical pond photo bioreactor of claim 1, wherein said bottom connector is provided with means for sparging air, COsub2 and delivery of nutrients into the algal solution, while displacing a conditioning fluid around the sleeve.
18. The vertical pond photo bioreactor of claim 1, wherein a selected number of said fins are substantially longer to serve as light guides.
19. The vertical pond photo bioreactor of claim 1, wherein the sleeve can be disinfected by UV or Gamma light.
20. The vertical pond photo bioreactor of claim 1, wherein the space between fins may be used as channels for collecting water resulting for dewatering the algal solution by said membrane.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2748225 CA2748225A1 (en) | 2011-07-11 | 2011-07-11 | Vertical pond photo bioreactor with low-cost thermal control system |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2748225 CA2748225A1 (en) | 2011-07-11 | 2011-07-11 | Vertical pond photo bioreactor with low-cost thermal control system |
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| CA2748225A1 true CA2748225A1 (en) | 2013-01-11 |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111558232A (en) * | 2020-05-18 | 2020-08-21 | 上海典硕生物科技有限公司 | Extraction element is used in production of disinfection spraying raw materials |
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2011
- 2011-07-11 CA CA 2748225 patent/CA2748225A1/en not_active Abandoned
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111558232A (en) * | 2020-05-18 | 2020-08-21 | 上海典硕生物科技有限公司 | Extraction element is used in production of disinfection spraying raw materials |
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