CA2836218A1 - Multilevel photobioreactor - Google Patents
Multilevel photobioreactor Download PDFInfo
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- CA2836218A1 CA2836218A1 CA2836218A CA2836218A CA2836218A1 CA 2836218 A1 CA2836218 A1 CA 2836218A1 CA 2836218 A CA2836218 A CA 2836218A CA 2836218 A CA2836218 A CA 2836218A CA 2836218 A1 CA2836218 A1 CA 2836218A1
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- C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
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- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
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- C12M21/00—Bioreactors or fermenters specially adapted for specific uses
- C12M21/02—Photobioreactors
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- C12M23/00—Constructional details, e.g. recesses, hinges
- C12M23/02—Form or structure of the vessel
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- C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
- C12M23/00—Constructional details, e.g. recesses, hinges
- C12M23/48—Holding appliances; Racks; Supports
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- C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
- C12M27/00—Means for mixing, agitating or circulating fluids in the vessel
- C12M27/16—Vibrating; Shaking; Tilting
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- C12N1/00—Microorganisms, e.g. protozoa; Compositions thereof; Processes of propagating, maintaining or preserving microorganisms or compositions thereof; Processes of preparing or isolating a composition containing a microorganism; Culture media therefor
- C12N1/12—Unicellular algae; Culture media therefor
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- C12P7/00—Preparation of oxygen-containing organic compounds
- C12P7/64—Fats; Fatty oils; Ester-type waxes; Higher fatty acids, i.e. having at least seven carbon atoms in an unbroken chain bound to a carboxyl group; Oxidised oils or fats
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Abstract
The present invention provides a modular low-cost, low energy multilevel photobioreactor for commercial scale-up. The bioreactor is comprising of multiple levels of stretched semi-rigid sheets that collectively create elongate shelves over which are laid elongate transparent sleeves, each sleeve incorporating two air sparger tubes.
Alternate pressurizing of air tubes creates agitation. The electronic control of agitators reduces substantially energy. Sleeves are laid over a mat of LEDs when operating in a warehouse or when the bioreactor is mounted in a shipping container. Another embodiment of the bioreactor operates in a greenhouse with natural light supplemented with LEDs.
Alternate pressurizing of air tubes creates agitation. The electronic control of agitators reduces substantially energy. Sleeves are laid over a mat of LEDs when operating in a warehouse or when the bioreactor is mounted in a shipping container. Another embodiment of the bioreactor operates in a greenhouse with natural light supplemented with LEDs.
Description
MULTILEVEL PHOTOBIOREACTOR
FIELD OF THE INVENTION
The present invention relates to a photobioreactor for production of biomass and more particularly to a multi-level shelf-like arrangement of elongate bioreactor bags or sleeves being supported horizontally over stretched transparent panels. In an embodiment of the invention, the modular bioreactor may be operated inside a warehouse or a container using artificial light. In another embodiment, the bioreactor operates inside a greenhouse using natural light.
DESCRIPTION
This patent application claims the benefit of priority from Canadian Patent Applications No. 2,801,768 filed Jan. 25, 2013 and from Application No. 2,764,291 filed Jan. 16, 2012 through PCT Application Serial No. PCT/CA2012/050750 filed Oct. 22, 2012 and published W0/2013/082713 on 13 June 2013, the contents of each of which are incorporated herein by reference.
BACKGROUND
The current energy crisis has prompted interest in altemative energy, bringing a great deal of attention to the production of algae biofuels. Beyond biofuels, commercial algae farming is also important to medicine, food, chemicals, aquaculture and production of feedstocks. One major obstacle to algae farming is the commercial scale-up for mass culture, temperature control of algae and the high cost associated with such a culture.
The vast number of different bioreactor concepts is testimony that the best algal farming bioreactors are still to be found. Most bioreactor designs are not suitable for commercial use due to cost and scale-up problems. In contrast with bioreactors, pond technologies are commercially viable today, but have well-established problems of their own.
Integrated technologies might provide the control present in closed bioreactors and the scalability provided by open ponds.
In Healthy Algae published by Fraunhofer Magazine, January 2002, it is stated that algae are a very undemanding life form - they only need water, carbon dioxyde, nutrients and sunlight. However, providing sufficient sunlight can be a problem in large scale facilities. As the algae at the surface absorb the light, it does not penetrate to a depth of more than a few millimeters. The organism inside the unit gets no light and cannot grow, explains Walter Troesch, who has been cultivating algae for years. One of the problems with growing algae in any kind of pond is that only in the top 1 inch to 4 inch or so of the pond receives sufficient solar radiation for the algae to grow. In effect, this means that the ability of a pond to grow algae is limited by its surface area, not by its volume.
Given that surface area of an algae container is more important than its volume, then all recent and past algae cultivators shall be re-examined in consideration of said criteria.
Traditional methods used for culturing autotrophic organisms have involved the use of shallow open ponds or open channels exposed to sunlight. Not surprisingly this comparatively crude method has proved impractical for production of pure high grade products because of such problems as invasion by hostile species (sometimes producing dangerous toxins), other pollution (such as dust and bird droppings), difficulty in the control of such variables as nutrient ratios, temperature and pH, intrinsically low yield because of escape of carbon dioxide to the atmosphere and inefficient use of light to illuminate only the top portion of the biomass.
Somewhat more sophisticated attempts have involved the use of horizontally disposed large diameter transparent plastics tubes laid on the ground for biomass production.
The problems of such a system include the low density of biomass in the liquid within the tubes, coating of the pipes by algae due to low velocity flow passing through, thus reducing transparency, overheating in summer weather, high land usage and high energy input to either agitate or move large amount of over diluted water.
To overcome some of the limitations of prior art, patent WO/2013/082713 issued to the present author, Mottahedeh, discloses a low-cost photobioreactor that provides a wide translucent flexible sheet that is shaped by external brackets to form an elongate channel adapted for biomass production therewithin. While an embodiment of this patent discloses bioreactor sheets that are shaped and supported in the air by suspended brackets, the Mottahedeh patent offers only limited compactness not sufficient for large commercial scale-up on a small footprint.
A closer look at receptacles disclosed in prior documents and more particularly for potential use as low-cost raceway-type pond or as photobioreactors, reveals that in the last five decades, since conception of early photobioreactors until now, people skilled in the art have strongly discouraged suspending or supporting horizontally-oriented structures above ground, particularly carrying heavy loads of liquids over suspended structures. This discouragement has been extended even further when liquids were to be carried and contained in flexible or semi-rigid containers. Objectors have argued that such an undertaking calls for extra support costs, requires additional structural stability or may be subject to environmental risks. Exceptionally, horizontally-oriented and elevated glass tubes of small diameter and more recently of polycarbonate material have been used at laboratory scale or for cultivating expensive microalgae in few pilot projects. It is therefore known that capital costs, installation and maintenance for such suspended tubular systems are exhorbitant.
Prior attempts to concentrate a large number of bioreactor containers on a small surface area include a multilayered photobioreactor disclosed in U.S. Patent 7,618,813 to Lee et al. which teaches primarily a series of vertical cylindrical photobioreactors limited to two or three layers of culture in same containers. It is known that vertical culture systems offer a low surface-to-volume ratio in terms of exposure to light. They also require large areas of land to be efficiently deployed.
Another attempt to stack multiple bioreactors next to each other is disclosed by Masse in U.S. Pat 7,997,025 who teaches an algae production with a harvesting apparatus.
The disclosed modular production system teaches stackable vertical-type photo-bioreactor modules adapted for producing algal bioproducts. Vertical, column-type bioreactors are known to require extra pumping pressure to overcome water pressure during gasing because of height. It is also known that in such column-type bioreactors sparging of C.O2 and 02 at high pressure causes shearing of algae cells as well as dead zones below and around nozzles, both sources of added contamination.
The photobioreactor disclosed by Levin in US Patent Application No.
teaches a large number of small troughs constructed from relatively short profiled units having bottoms provided with recesses or transverse low partitions. The system is provided with feeding pipes having nozzles delivering the microalgae suspension to the troughs and a pumping system that feeds the system. Throughs are built on two parallel ropes or parallel rods. When troughs are sufficiently rigid, they are installed at their ends immediately on the vertical posts without application of the ropes. Levin further discloses that the entire set of the vertical rows of the troughs with optical elements positioned between these vertical rows can be placed in a greenhouse construction which prevents ingress of the dust into the microalgae suspension. This Levin patent discloses a system of narrow open troughs suspended to ropes or rods. Despite its complexity, troughs are still left open and rely on an external greenhouse cover to prevent contamination or cross-contamination.
Accordingly, there is a need for an algae production system suitable for the mass production of algae. Addressing such a need requires that past objections and long standing prejudices against horizontally supported flexible bioreactors being suspended in the air be re-examined.
What is needed is an apparatus that overcomes the aforementioned limitations, prejudices and disadvantages of prior art while being cost effective and able to integrate the scalability provided by ponds with the controls provided by photobiorectors.
Preferably, inventive steps disregarding past prejudices would lead to an apparatus configured with a large surface-to-volume ratio while erectable on a small footprint, easy to maintain, to operate and to scale-up.
SUMMARY OF THE INVENTION
The disclosed bioreactor is generally directed to a modular multilevel photo bioreactor suitable for mass culture of algal biomass being either exposed to artificial light, to solar light or to a combination thereof.
The modular bioreactor of the invention can be extended longitudinally, vertically and to some extend transversally. It features a surface area as large as the number of its levels while standing on a footprint equivalent to only a single level.
Each bioreactor level is made of transparent shelves. Depending on the bioreactor size and configuration, shelves form collectively one or two flat horizontal elongate surfaces over which are laid elongate bioreactor bags or sleeves. Each sleeve incorporates at least two sparger tubes, each being alternately pressurized by an aeration pump. An electronic switching system turns on and off air pressure between the two sparger tubes creating transversal waves, vibrations and agitation along the full length of the sleeves.
Having intemal sparger tubes built-in into a bioreactor sleeve reduces sources of contamination caused by introduction of external sparger tubes. The compactness provided by the present multilevel bioreactor improves monitoring and control of factors that influence generally the operation of a bioreactor. Such factors include temperature, light, pH, agitation, gas flow and liquid flow and physical factors of the like.
The bioreactor is expandable with modular components that may be arranged in a manner that facilitates efficient deployment and maintenance. The unique arrangement of its horizontal shelves, each being independently secured, at each rack level, to opposite upright posts, avoids the vertical build-up of pressure among bioreactor sleeves; this arrangement departs fundamentally from prior art bioreactors wherein the taller a bioreactor is raised, the more pressure is required to overcome flow of gases needed to feed algae and to agitate the system; this problem affects negatively all vertical bioreactors, whether panel-like, column-like, cylindrical-like or bag-types.
Furthermore, the present multilevel bioreactor takes advantage of gravity ¨ a medium entering higher level sleeves may freely flow into lower level bags after being exposed to light along the full length of said sleeves while travelling across the selected horizontal shelves. This arrangement again saves substantially energy and costs.
Furthermore, providing a multilevel bioreactor enables to allocate different processes to different sleeves located at various levels, all within the same bioreactor.
As an example, to dewater an algal culture, the cultured algae may be directed towards a bioreactor sleeve positioned at a lower level wherein a natural filtration by gravity may take place.
Thus reducing substantially the amount of energy associated to dewatering.
In an embodiment of the invention, the multilevel bioreactor is operated in a warehouse, in a building or fitted modularly to operate a shipping cargo using artificial light such as light emitting diodes LED, including embedded LEDs in a mat. In another embodiment of the invention, the multilevel bioreactor is surrounded by a circular-shape greenhouse cover in which the lower portion of the cover close to the ground takes on a parabolic shape covered by a reflective material.
The advantages of the invention will be set forth in part in the description which follows, and in part will be understood from the description, or may be learned by practice of the disclosure herein. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the invention will become apparent upon reading the detailed description and upon referring to the drawings in which:
Figure 1 is a cross-sectional front view of two superimposed sleeves of the multilevel photo bioreactor.
Figure 2 is a front view of a multilevel photo bioreactor surrounded by a greenhouse cover.
Figure 3 is a perspective view of the bioreactor of Figure 2.
Figure 4 is a cross-sectional side view of a sleeve with a movable roller separating fluid content in two portions.
Figure 5 is a perspective back view of the bioreactor showing replacement rollers.
Figure 6 is a cross-sectional view of a bioreactor sleeve provided with a water jacket.
Figure 7 is a cross-sectional view of a bioreactor sleeve provided with a filter membrane inside.
Figure 8 is a perspective view of two flexible light emitting diode LED mats.
Figure 9 is a perspective view of a bioreactor fitted into a shipping container.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
The present invention best described in FIG. 1 provides a multilevel photobioreactor 500 comprising an assembly of self-standing modular frames 62 each comprising a set of opposite rack uprights 62 having feet anchored to the ground and tops connected by horizontal beams.
Multiple levels of transparent horizontal thin hammock-like shelves 82 are stretched between said rack uprights 62. Shelves 82 are comprised of transparent, semi-rigid plastic sheets having two opposite borders secured to rigid metal profiles by fasteners means such as industrial staples. In tum, said rigid metal profiles are tightly stretched by fasteners means 94 between rack uprights 62. The degree of stretch of said semi-rigid sheets 82 determines the degree of deflection anticipated by the shelf 82 under load when bioreactor sleeve 100 is loaded.
In a preferred embodiment of the bioreactor 500 as best described in FIG. 2, multiple transversally-oriented adjacent shelves 82 form collectively side-by-side at each level, two adjacent columns of longitudinal shelves 82. On these tightly stretched horizontal shelves 82 are laid bioreactor sleeves 100, each shelf level being itself created by multiple rows of flat horizontal stretched panels 84; each shelf 82 being adapted to support a wide elongate sleeve or bag 100 that contains an algal medium. In between columns, a repeating number of vertical perforated plates supports horizontal elongate middle bars 64 to support load at the center of panels 84.
In another embodiment of the invention, longitudinally-oriented panels 84 form collectively at each level, a single column, each including multiple levels of flat horizontal elongate surfaces or shelves 82; each shelf 82 adapted to support a wide elongate sleeve or bag 100 that contains an algal medium.
Sleeves 100 are preferably made of an upper 14 and a lower 12 light-penetrating transparent or translucent layer of flexible plastic sheets having their longitudinal edges sealed together for creating a container means 100 adapted for biomass production. In the preferred embodiment of the invention, the bottom sheet layer 12 incorporates two sparger tubes 22 and 24 for dispensing gases along the sleeve 100 full length.
Sparger tubes 22, 24 are shaped by respectively folding, perforating and sealing a sleeve 100 bottom member portion 12 along the full sleeve member 100 length.
It is known that in any photosynthetically-driven algae farming system, proper agitation of algal medium is critical to expose all algae cells to light, no matter medium depth.
Traditionally, substantial amount of energy is allocated to agitation of the algal medium.
To reduce this energy consumption, the present invention discloses two low energy agitation systems.
In a first embodiment of the agitation system, an algal medium 42 contained in sleeve 100 is agitated by gases. This is achieved by alternately pressurizing each of the two or more sparger tubes 22, 24 provided with their own holes 17 positioned at the bottom of the sleeve member 12. Pressure variation in sparger tubes 22, 24 creates a transversal harmonic agitation along the full length of sleeve 100 creating waves that mix intimately gases with the algal medium.
In a second embodiment of the agitation system, physical vibration of air exiting from sparger tubes 22, 24 is used as a source of agitation, adding to the agitation created by bursting bubbles 32 that exit from same tubes 22, 24. To increase vibration, a pressure pulsation similar to "water-hammer" in liquids is created in sparger tubes 22, 24.
Vibrations may be also be generated using a venturi effect caused by releasing a pressurized but un-even air flow via small orifices positioned along the two sides of the thin air sparger tubes 22, 24 positioned under algal medium.
Volume and pressure fluctuation of gases generated in sparger tubes 22, 24 is created by adding to an air or carbon dioxide gas delivery system a means such as, but not limited to, modified diaphragm, a floating tongue, an unbalanced or balanced rotor, an unbalanced or balanced propeller, an electrically-driven modulator or a combination thereof.
As shown in FIGS. 1, to remove oxygen from the bioreactor sleeve 100, at least one elongate border portion of sleeve 100 is elevated above fluid level and secured to a railing-type support 92. This creates space for vents to be inserted into the bioreactor sleeve 100 to vent excess gases. To achieve this, a folded portion of the sleeve walls 12, 14 is sealed and laced with a rope-like filler that can be removably engaged in railing 92 attached to the side of an upper shelf located just above shelf 82 that supports said sleeve 100. The filler means includes foam rope, plastic rope, jute rope and cotton rope. Such an arrangement makes installation, retrieving and maintenance of sleeves 100 easy.
In an embodiment of the invention, the multilevel photobioreactor 500 includes a source of artificial light such as LED tapes 202, LED bars, LED lamps or LED mats 210 as shown in FIG. 7. These are positionable under, above or at the side of sleeve members 100 or according to a combination of said locations.
The source of light may also include solar light in combination with artificial light. In a preferred embodiment the light source, multiple parallel rows of light emitting diodes LED are positioned over a mat 210. They are provided with select wavelengths that enhance algae growth. They are either embedded, sandwiched and laminated between two transparent films to form collectively a wide, flexible, modular transparent mat 210 that may be electrically connected via connectors 212 among themselves and powered by an electrical source.
Fluid level and flow from one or multiple sleeves 100 located on a higher shelf 82 to sleeves located on lower shelves 82 may be controlled via height-adjustable fluid exit means 19 such as height-adjustable overflow valves 19 to establish the desired level of fluid in each sleeve 100 before extra fluid overflows to another destination;
said valves 19 being positioned at one or both ends of each sleeve 100.
To engage different individual or groups of sleeves 100 to perform different tasks or processes in a same multilevel bioreactor 500, valves 19 may be opened or closed manually or automatically enabling fluid flow in a sleeve 100 in a vertical downward direction, in a horizontal sideway direction from left to right or vice-versa, or follow a pattern programmable by a controller means (not shown). As an example, six upper levels of sleeves 100 may be engaged in culture of an algae species receiving air, C.O2, agitation and nutrients, whereas three lower levels of algal medium may be cut off from air and nutrients to undergo a starvation process forcing them to transform their biomass into oil, and finally three lowest levels may be used as transfer containers to maintain continuity of the process.
Thus, having multiple sleeves 100 so densely located next to each other enables to subject algae to collaborative processes including extreme environmental conditions and shocks that stimulate algae growth. Such environmental treatment may include subjecting them to high or low electromagnetic fields, high or low flashes of light, flashes of heat, exposure to sound waves, and a combination thereof.
Providing sleeves 100 whose weight is independently carried by shelves 82 which are in turn affixed to the rack system 62 eliminates transfer or accumulation of weight or fluid pressure being exercised on lower sleeves 100. This eliminates the need for pumps to operate under higher pressures such as for aerating the bioreactor system 500 or displacing fluids. This saves energy and reduces substantially operation costs.
In the present photobioreactor of the invention 500, biofilm or deposits from sedimentation in sleeves 100 may be removed by displacing manually, automatically or by pressure differential means a movable cleaning pig (not shown) in the sleeve 100. To achieve this, a mop-shape cleaning pig attached to two ropes, one on each side of the cleaning pig, may be pulled.
In an embodiment of the bioreactor exposed to solar light 1000, to prevent photo inhibition, the transparent or translucent material that composes the sleeve 100 may be adapted to allow only photosynthetically active radiation (PAR) wavelengths of about 400 nm to 700 nm to reach an algal medium contained in the sleeves 100.
In the preferred embodiment of the bioreactor 500, the sleeves 100 are sized to be about 0.5m to about 4m wide, but preferably about 1.2m to about 2,4m wide;
rack uprights 62 are about 50cm to about 6m high but preferably about 2.4m to about 3.6m high; bioreactor 500 length extends between about 1.2m to about 100m long but are preferably about 2.4m to about 50m long.
The photobioreactor 500 is provided with about 2 to about 40 levels of shelves 82, but preferably about 19 to about 30 shelf levels; each panel 84 making collectively shelves 84 is substantially about 0.010" (0.254mm) to about 0.080" (2.032mm) thick, but preferably about 0.02" (0.508mm) to about 0.03" (0.762mm) thick; and the elongate sleeves 100 are about 2 Mil (50.8micron) to about 12 Mil (304.8micron) thick but preferably about 4 Mil (101.6 micron) to about 8 Mil (203.2micron) thick.
In another embodiment of the bioreactor 500 shown in FIG. 7 the sleeve member 100 is comprising, in addition to an upper 14 and a lower 12 flexible sheet portion, a middle detachable filter sheet portion 16 adapted to dewater the algal medium and retain a thin layer of biomass body above the filter sheet 16 when ends or bottom of said sleeve CA 02836217 203.3-12-13 lower sheet portion 12 is opened, enabling fluid contained in the sleeve member 100 to escape and, or be recycled.
In yet another embodiment of the sleeve member 100, the sleeve member has a middle filter sheet portion 16 adapted to be disconnected from the sleeve upper 14 and lower sheet portions 12 and can be carried away by a conveyor belt into a heating zone able to dry and transform said biomass into thin peelable biomass crust.
In an embodiment of the multilevel photobioreactor 500 shown in FIG. 5, a biomass dewatering system 400 is further provided. The dewatering system 400 is comprising an elongate motorized conveyor belt located in a trough 420 that is positioned at the lowest level of bioreactor 500; the belt of the conveyor also functions as a filter 16 adapted to receive and partially dewater biomass. Filter / belt 16 is being exposed to a heating zone that dries and transforms the thin layer of biomass into a peelable crust collected by gravity.
Bioreactors 500 of the inventions have tightly stretched shelves 82 or panels 84 that may support one or two lines of elongate sleeve members 100. When two lines of sleeve members are laid on shelves 82 or on panels 84, a central support system 64 is being provided.
While some embodiments of bioreactor 500 are adapted to operate indoor, inside a warehouse, a shipping container 600 (see FIG. 9) or inside any other closed structure or building; other embodiments of bioreactor 500 are configured to operate outdoor, protected from weather conditions under structures such a greenhouse 1000 or an inflatable structure. In such a configuration, the elongate bioreactor 500 is located at the center of the tunnel-shape greenhouse 1000 with the cover being adapted to provide optimum photosynthetically active radiation (PAR) within wavelengths ranging about 400nm to 700nm with about 95% light diffusion; the lower portion of the greenhouse 1000 is provided with a reflective portion 210 having a parabola-shape configuration. The reflective material 210 may be flexible or semi-rigid and is adapted to reflect incoming light towards sleeves 100.
In an embodiment of the invention (FIG. 5), replacement of disposable or re-usable bioreactor container means or sleeves 100 is made easy by providing a stand (not shown) holding multiple rollers 18; the stand is located at one end of bioreactor 500 for holding a supply of rolls 18 of flexible container means 100; pulling out, from one end of bioreactor 500 a container means portion 100 causes a supply of fresh container means portion 100 to be dispensed from a corresponding roll 18 located at the other end of bioreactor 500; thus an empty or partially dewatered container means portion 100 may be easily and readily (after dewatering) replaced by a fresh un-contaminated container means portion 100. Replacement of an older container means may take place because of damage, leakage, contamination, wear and tear, loss of clarity or as part of a processing step wherein biomass contained in the container means 100 may be collected and further processed.
As an example of a processing step, a dewatered container means portion 100 may be gradually pulled out of the bioreactor shelves 82, sealed and then separated into small packages; this guarantees avoidance of contact with air or other extemal sources of contamination. In a further step, the sealed packages may be safely transported, frozen or directly sold to consumers or to buyers.
CA 02836217 2013-12-3.3 The bioreactor of the present invention 500 provides a controlled environment in which multiple parallel or serial processes may occur within a container means 100 of bioreactor 500 itself or in association with equipment and accessories that are in air or fluid communication with container means 100 or are introduced in said container means 100. As an example, in the present invention internal layers of said container means 100 may function as filtering membranes 16 having their own sparger tubes 22, 24 with holes 17 along their full length. When dealing with fluids of different densities, intemal layers may transfer or filter fluids via osmosis or reverse osmosis.
In another example, introducing venturi jets into the algal medium creates micro bubbles that separate solids from liquids and lift agglomerated cells to the fluid surface making harvesting of microalgae easy as a simple skimming process. Other processing steps within the bioreactor container means 100 may include electro flocculation, bioflocculation, blofloatation, fermentation, lysing, hydrogenation, localized heat treatment, localized light flash treatment, localized high or low magnetic field treatment;
some of said processes causing stresses that may increase biomass productivity or influence it; yet another example include oil extraction by fracturing cells walls with cavitational micro-bubbles, and a combination of multiple processes mentioned before.
The multilevel photobioreactor 500 is best made of at least one of the materials selected from the group consisting of: fiber reinforced plastic, low density polyethylene, high-density polyethylene, nylon, hard acrylic, polyvinyl chloride, polycarbonate, composite plastic, ethylene vinyl acetate, fiber glass, woven fabrics, non-woven fabrics and a combination thereof.
In an embodiment of the photobioreactor 500, the modular bioreactor 500 is encased and installed in a steel structure such as a shipping container 600; grouping multiple shipping containers 600 together scales-up fast installation of bioreactor 500.
In yet another embodiment of invention 500 shown in FIG. 6, thermal control of the bioreactor 500 is provided by circulating a cooling or heating fluid 40 in a water jacket 20; the water jacket 20 is created by positioning an elongate bag 120 longitudinally just below panels 84 and above a surface created by a repeating number of modular supports 86. Supports 86 are simply made by doubling panels 84 with a slight difference.
While they share same two opposite borders and respective holding attachments for tightening them, upper panels 84 are tightly stretched while lower panels 86 are loosely stretched and secured to opposite rack uprights 62; the upper tightly stretched panel 84 is sized to be of slightly shorter length that of the lower loosely stretched panel 86; in such an arrangement, lower loosely stretched panels 86 form collectively an elongate surface 88 over which may be extended a long flexible or semi-rigid shallow chamber or jacket 20. Circulating a slightly pressurized hot or cold fluid 40 in said shallow chamber 20 causes chamber 20 to press upwardly against the bottom of the upper tightly stretched panel 84 and exchange its heat or cold with bioreactor sleeve 100.
Depth of said shallow chamber 20 may vary between about 10mm to about 50mm at its lowest point.
In another embodiment of the invention, cooling of bioreactor 600 is achieved by evaporating dew very slowly seeping out from bioreactor container means upper wall 14.
To optimize cooling by evaporation, the container means 100 is having, preferably a top wail 14, a bottom wall 12, or both walls 12, 14 made of a transparent waterproof material that is breathable to enable very slow evaporation of condensates under a warm climate.
To expand inoculum gradually, controllably and safely without being exposed to contamination, mainly during traditional transfer of medium to larger containers has been a challenge among algae farmers. To overcome this challenge, the present bioreactor 500 provides an external movable divider 310 that enables a full volume of medium 42 contained in each of the container means 100 to be divided, then isolated and then expanded in a controlled manner; control of expansion being achieved by simple rolling or sliding one or multiple movable dividers 310 that are positionable under walls 12 and 14 of the flexible container means 100; said dividers 310 elevating and isolating a portion of said container means 100 include, but not limited to, movable rollers 310, liftable bars, roller-over-bars, stretchable bungees, ropes, cables, raisable panels, slidable self-standing dividers and a combination thereof.
To channel and collect water from spills or leakage from the bioreactor container means 100, a waterproof sheet positioned at the lowest level of the bioreactor 500 is provided with elongate borders being loosely stretched between the bioreactor opposite rack uprights 62; said waterproof sheet is further provided with a drainage means connected to hoses that carry water spills away.
The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.
FIELD OF THE INVENTION
The present invention relates to a photobioreactor for production of biomass and more particularly to a multi-level shelf-like arrangement of elongate bioreactor bags or sleeves being supported horizontally over stretched transparent panels. In an embodiment of the invention, the modular bioreactor may be operated inside a warehouse or a container using artificial light. In another embodiment, the bioreactor operates inside a greenhouse using natural light.
DESCRIPTION
This patent application claims the benefit of priority from Canadian Patent Applications No. 2,801,768 filed Jan. 25, 2013 and from Application No. 2,764,291 filed Jan. 16, 2012 through PCT Application Serial No. PCT/CA2012/050750 filed Oct. 22, 2012 and published W0/2013/082713 on 13 June 2013, the contents of each of which are incorporated herein by reference.
BACKGROUND
The current energy crisis has prompted interest in altemative energy, bringing a great deal of attention to the production of algae biofuels. Beyond biofuels, commercial algae farming is also important to medicine, food, chemicals, aquaculture and production of feedstocks. One major obstacle to algae farming is the commercial scale-up for mass culture, temperature control of algae and the high cost associated with such a culture.
The vast number of different bioreactor concepts is testimony that the best algal farming bioreactors are still to be found. Most bioreactor designs are not suitable for commercial use due to cost and scale-up problems. In contrast with bioreactors, pond technologies are commercially viable today, but have well-established problems of their own.
Integrated technologies might provide the control present in closed bioreactors and the scalability provided by open ponds.
In Healthy Algae published by Fraunhofer Magazine, January 2002, it is stated that algae are a very undemanding life form - they only need water, carbon dioxyde, nutrients and sunlight. However, providing sufficient sunlight can be a problem in large scale facilities. As the algae at the surface absorb the light, it does not penetrate to a depth of more than a few millimeters. The organism inside the unit gets no light and cannot grow, explains Walter Troesch, who has been cultivating algae for years. One of the problems with growing algae in any kind of pond is that only in the top 1 inch to 4 inch or so of the pond receives sufficient solar radiation for the algae to grow. In effect, this means that the ability of a pond to grow algae is limited by its surface area, not by its volume.
Given that surface area of an algae container is more important than its volume, then all recent and past algae cultivators shall be re-examined in consideration of said criteria.
Traditional methods used for culturing autotrophic organisms have involved the use of shallow open ponds or open channels exposed to sunlight. Not surprisingly this comparatively crude method has proved impractical for production of pure high grade products because of such problems as invasion by hostile species (sometimes producing dangerous toxins), other pollution (such as dust and bird droppings), difficulty in the control of such variables as nutrient ratios, temperature and pH, intrinsically low yield because of escape of carbon dioxide to the atmosphere and inefficient use of light to illuminate only the top portion of the biomass.
Somewhat more sophisticated attempts have involved the use of horizontally disposed large diameter transparent plastics tubes laid on the ground for biomass production.
The problems of such a system include the low density of biomass in the liquid within the tubes, coating of the pipes by algae due to low velocity flow passing through, thus reducing transparency, overheating in summer weather, high land usage and high energy input to either agitate or move large amount of over diluted water.
To overcome some of the limitations of prior art, patent WO/2013/082713 issued to the present author, Mottahedeh, discloses a low-cost photobioreactor that provides a wide translucent flexible sheet that is shaped by external brackets to form an elongate channel adapted for biomass production therewithin. While an embodiment of this patent discloses bioreactor sheets that are shaped and supported in the air by suspended brackets, the Mottahedeh patent offers only limited compactness not sufficient for large commercial scale-up on a small footprint.
A closer look at receptacles disclosed in prior documents and more particularly for potential use as low-cost raceway-type pond or as photobioreactors, reveals that in the last five decades, since conception of early photobioreactors until now, people skilled in the art have strongly discouraged suspending or supporting horizontally-oriented structures above ground, particularly carrying heavy loads of liquids over suspended structures. This discouragement has been extended even further when liquids were to be carried and contained in flexible or semi-rigid containers. Objectors have argued that such an undertaking calls for extra support costs, requires additional structural stability or may be subject to environmental risks. Exceptionally, horizontally-oriented and elevated glass tubes of small diameter and more recently of polycarbonate material have been used at laboratory scale or for cultivating expensive microalgae in few pilot projects. It is therefore known that capital costs, installation and maintenance for such suspended tubular systems are exhorbitant.
Prior attempts to concentrate a large number of bioreactor containers on a small surface area include a multilayered photobioreactor disclosed in U.S. Patent 7,618,813 to Lee et al. which teaches primarily a series of vertical cylindrical photobioreactors limited to two or three layers of culture in same containers. It is known that vertical culture systems offer a low surface-to-volume ratio in terms of exposure to light. They also require large areas of land to be efficiently deployed.
Another attempt to stack multiple bioreactors next to each other is disclosed by Masse in U.S. Pat 7,997,025 who teaches an algae production with a harvesting apparatus.
The disclosed modular production system teaches stackable vertical-type photo-bioreactor modules adapted for producing algal bioproducts. Vertical, column-type bioreactors are known to require extra pumping pressure to overcome water pressure during gasing because of height. It is also known that in such column-type bioreactors sparging of C.O2 and 02 at high pressure causes shearing of algae cells as well as dead zones below and around nozzles, both sources of added contamination.
The photobioreactor disclosed by Levin in US Patent Application No.
teaches a large number of small troughs constructed from relatively short profiled units having bottoms provided with recesses or transverse low partitions. The system is provided with feeding pipes having nozzles delivering the microalgae suspension to the troughs and a pumping system that feeds the system. Throughs are built on two parallel ropes or parallel rods. When troughs are sufficiently rigid, they are installed at their ends immediately on the vertical posts without application of the ropes. Levin further discloses that the entire set of the vertical rows of the troughs with optical elements positioned between these vertical rows can be placed in a greenhouse construction which prevents ingress of the dust into the microalgae suspension. This Levin patent discloses a system of narrow open troughs suspended to ropes or rods. Despite its complexity, troughs are still left open and rely on an external greenhouse cover to prevent contamination or cross-contamination.
Accordingly, there is a need for an algae production system suitable for the mass production of algae. Addressing such a need requires that past objections and long standing prejudices against horizontally supported flexible bioreactors being suspended in the air be re-examined.
What is needed is an apparatus that overcomes the aforementioned limitations, prejudices and disadvantages of prior art while being cost effective and able to integrate the scalability provided by ponds with the controls provided by photobiorectors.
Preferably, inventive steps disregarding past prejudices would lead to an apparatus configured with a large surface-to-volume ratio while erectable on a small footprint, easy to maintain, to operate and to scale-up.
SUMMARY OF THE INVENTION
The disclosed bioreactor is generally directed to a modular multilevel photo bioreactor suitable for mass culture of algal biomass being either exposed to artificial light, to solar light or to a combination thereof.
The modular bioreactor of the invention can be extended longitudinally, vertically and to some extend transversally. It features a surface area as large as the number of its levels while standing on a footprint equivalent to only a single level.
Each bioreactor level is made of transparent shelves. Depending on the bioreactor size and configuration, shelves form collectively one or two flat horizontal elongate surfaces over which are laid elongate bioreactor bags or sleeves. Each sleeve incorporates at least two sparger tubes, each being alternately pressurized by an aeration pump. An electronic switching system turns on and off air pressure between the two sparger tubes creating transversal waves, vibrations and agitation along the full length of the sleeves.
Having intemal sparger tubes built-in into a bioreactor sleeve reduces sources of contamination caused by introduction of external sparger tubes. The compactness provided by the present multilevel bioreactor improves monitoring and control of factors that influence generally the operation of a bioreactor. Such factors include temperature, light, pH, agitation, gas flow and liquid flow and physical factors of the like.
The bioreactor is expandable with modular components that may be arranged in a manner that facilitates efficient deployment and maintenance. The unique arrangement of its horizontal shelves, each being independently secured, at each rack level, to opposite upright posts, avoids the vertical build-up of pressure among bioreactor sleeves; this arrangement departs fundamentally from prior art bioreactors wherein the taller a bioreactor is raised, the more pressure is required to overcome flow of gases needed to feed algae and to agitate the system; this problem affects negatively all vertical bioreactors, whether panel-like, column-like, cylindrical-like or bag-types.
Furthermore, the present multilevel bioreactor takes advantage of gravity ¨ a medium entering higher level sleeves may freely flow into lower level bags after being exposed to light along the full length of said sleeves while travelling across the selected horizontal shelves. This arrangement again saves substantially energy and costs.
Furthermore, providing a multilevel bioreactor enables to allocate different processes to different sleeves located at various levels, all within the same bioreactor.
As an example, to dewater an algal culture, the cultured algae may be directed towards a bioreactor sleeve positioned at a lower level wherein a natural filtration by gravity may take place.
Thus reducing substantially the amount of energy associated to dewatering.
In an embodiment of the invention, the multilevel bioreactor is operated in a warehouse, in a building or fitted modularly to operate a shipping cargo using artificial light such as light emitting diodes LED, including embedded LEDs in a mat. In another embodiment of the invention, the multilevel bioreactor is surrounded by a circular-shape greenhouse cover in which the lower portion of the cover close to the ground takes on a parabolic shape covered by a reflective material.
The advantages of the invention will be set forth in part in the description which follows, and in part will be understood from the description, or may be learned by practice of the disclosure herein. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the invention will become apparent upon reading the detailed description and upon referring to the drawings in which:
Figure 1 is a cross-sectional front view of two superimposed sleeves of the multilevel photo bioreactor.
Figure 2 is a front view of a multilevel photo bioreactor surrounded by a greenhouse cover.
Figure 3 is a perspective view of the bioreactor of Figure 2.
Figure 4 is a cross-sectional side view of a sleeve with a movable roller separating fluid content in two portions.
Figure 5 is a perspective back view of the bioreactor showing replacement rollers.
Figure 6 is a cross-sectional view of a bioreactor sleeve provided with a water jacket.
Figure 7 is a cross-sectional view of a bioreactor sleeve provided with a filter membrane inside.
Figure 8 is a perspective view of two flexible light emitting diode LED mats.
Figure 9 is a perspective view of a bioreactor fitted into a shipping container.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
The present invention best described in FIG. 1 provides a multilevel photobioreactor 500 comprising an assembly of self-standing modular frames 62 each comprising a set of opposite rack uprights 62 having feet anchored to the ground and tops connected by horizontal beams.
Multiple levels of transparent horizontal thin hammock-like shelves 82 are stretched between said rack uprights 62. Shelves 82 are comprised of transparent, semi-rigid plastic sheets having two opposite borders secured to rigid metal profiles by fasteners means such as industrial staples. In tum, said rigid metal profiles are tightly stretched by fasteners means 94 between rack uprights 62. The degree of stretch of said semi-rigid sheets 82 determines the degree of deflection anticipated by the shelf 82 under load when bioreactor sleeve 100 is loaded.
In a preferred embodiment of the bioreactor 500 as best described in FIG. 2, multiple transversally-oriented adjacent shelves 82 form collectively side-by-side at each level, two adjacent columns of longitudinal shelves 82. On these tightly stretched horizontal shelves 82 are laid bioreactor sleeves 100, each shelf level being itself created by multiple rows of flat horizontal stretched panels 84; each shelf 82 being adapted to support a wide elongate sleeve or bag 100 that contains an algal medium. In between columns, a repeating number of vertical perforated plates supports horizontal elongate middle bars 64 to support load at the center of panels 84.
In another embodiment of the invention, longitudinally-oriented panels 84 form collectively at each level, a single column, each including multiple levels of flat horizontal elongate surfaces or shelves 82; each shelf 82 adapted to support a wide elongate sleeve or bag 100 that contains an algal medium.
Sleeves 100 are preferably made of an upper 14 and a lower 12 light-penetrating transparent or translucent layer of flexible plastic sheets having their longitudinal edges sealed together for creating a container means 100 adapted for biomass production. In the preferred embodiment of the invention, the bottom sheet layer 12 incorporates two sparger tubes 22 and 24 for dispensing gases along the sleeve 100 full length.
Sparger tubes 22, 24 are shaped by respectively folding, perforating and sealing a sleeve 100 bottom member portion 12 along the full sleeve member 100 length.
It is known that in any photosynthetically-driven algae farming system, proper agitation of algal medium is critical to expose all algae cells to light, no matter medium depth.
Traditionally, substantial amount of energy is allocated to agitation of the algal medium.
To reduce this energy consumption, the present invention discloses two low energy agitation systems.
In a first embodiment of the agitation system, an algal medium 42 contained in sleeve 100 is agitated by gases. This is achieved by alternately pressurizing each of the two or more sparger tubes 22, 24 provided with their own holes 17 positioned at the bottom of the sleeve member 12. Pressure variation in sparger tubes 22, 24 creates a transversal harmonic agitation along the full length of sleeve 100 creating waves that mix intimately gases with the algal medium.
In a second embodiment of the agitation system, physical vibration of air exiting from sparger tubes 22, 24 is used as a source of agitation, adding to the agitation created by bursting bubbles 32 that exit from same tubes 22, 24. To increase vibration, a pressure pulsation similar to "water-hammer" in liquids is created in sparger tubes 22, 24.
Vibrations may be also be generated using a venturi effect caused by releasing a pressurized but un-even air flow via small orifices positioned along the two sides of the thin air sparger tubes 22, 24 positioned under algal medium.
Volume and pressure fluctuation of gases generated in sparger tubes 22, 24 is created by adding to an air or carbon dioxide gas delivery system a means such as, but not limited to, modified diaphragm, a floating tongue, an unbalanced or balanced rotor, an unbalanced or balanced propeller, an electrically-driven modulator or a combination thereof.
As shown in FIGS. 1, to remove oxygen from the bioreactor sleeve 100, at least one elongate border portion of sleeve 100 is elevated above fluid level and secured to a railing-type support 92. This creates space for vents to be inserted into the bioreactor sleeve 100 to vent excess gases. To achieve this, a folded portion of the sleeve walls 12, 14 is sealed and laced with a rope-like filler that can be removably engaged in railing 92 attached to the side of an upper shelf located just above shelf 82 that supports said sleeve 100. The filler means includes foam rope, plastic rope, jute rope and cotton rope. Such an arrangement makes installation, retrieving and maintenance of sleeves 100 easy.
In an embodiment of the invention, the multilevel photobioreactor 500 includes a source of artificial light such as LED tapes 202, LED bars, LED lamps or LED mats 210 as shown in FIG. 7. These are positionable under, above or at the side of sleeve members 100 or according to a combination of said locations.
The source of light may also include solar light in combination with artificial light. In a preferred embodiment the light source, multiple parallel rows of light emitting diodes LED are positioned over a mat 210. They are provided with select wavelengths that enhance algae growth. They are either embedded, sandwiched and laminated between two transparent films to form collectively a wide, flexible, modular transparent mat 210 that may be electrically connected via connectors 212 among themselves and powered by an electrical source.
Fluid level and flow from one or multiple sleeves 100 located on a higher shelf 82 to sleeves located on lower shelves 82 may be controlled via height-adjustable fluid exit means 19 such as height-adjustable overflow valves 19 to establish the desired level of fluid in each sleeve 100 before extra fluid overflows to another destination;
said valves 19 being positioned at one or both ends of each sleeve 100.
To engage different individual or groups of sleeves 100 to perform different tasks or processes in a same multilevel bioreactor 500, valves 19 may be opened or closed manually or automatically enabling fluid flow in a sleeve 100 in a vertical downward direction, in a horizontal sideway direction from left to right or vice-versa, or follow a pattern programmable by a controller means (not shown). As an example, six upper levels of sleeves 100 may be engaged in culture of an algae species receiving air, C.O2, agitation and nutrients, whereas three lower levels of algal medium may be cut off from air and nutrients to undergo a starvation process forcing them to transform their biomass into oil, and finally three lowest levels may be used as transfer containers to maintain continuity of the process.
Thus, having multiple sleeves 100 so densely located next to each other enables to subject algae to collaborative processes including extreme environmental conditions and shocks that stimulate algae growth. Such environmental treatment may include subjecting them to high or low electromagnetic fields, high or low flashes of light, flashes of heat, exposure to sound waves, and a combination thereof.
Providing sleeves 100 whose weight is independently carried by shelves 82 which are in turn affixed to the rack system 62 eliminates transfer or accumulation of weight or fluid pressure being exercised on lower sleeves 100. This eliminates the need for pumps to operate under higher pressures such as for aerating the bioreactor system 500 or displacing fluids. This saves energy and reduces substantially operation costs.
In the present photobioreactor of the invention 500, biofilm or deposits from sedimentation in sleeves 100 may be removed by displacing manually, automatically or by pressure differential means a movable cleaning pig (not shown) in the sleeve 100. To achieve this, a mop-shape cleaning pig attached to two ropes, one on each side of the cleaning pig, may be pulled.
In an embodiment of the bioreactor exposed to solar light 1000, to prevent photo inhibition, the transparent or translucent material that composes the sleeve 100 may be adapted to allow only photosynthetically active radiation (PAR) wavelengths of about 400 nm to 700 nm to reach an algal medium contained in the sleeves 100.
In the preferred embodiment of the bioreactor 500, the sleeves 100 are sized to be about 0.5m to about 4m wide, but preferably about 1.2m to about 2,4m wide;
rack uprights 62 are about 50cm to about 6m high but preferably about 2.4m to about 3.6m high; bioreactor 500 length extends between about 1.2m to about 100m long but are preferably about 2.4m to about 50m long.
The photobioreactor 500 is provided with about 2 to about 40 levels of shelves 82, but preferably about 19 to about 30 shelf levels; each panel 84 making collectively shelves 84 is substantially about 0.010" (0.254mm) to about 0.080" (2.032mm) thick, but preferably about 0.02" (0.508mm) to about 0.03" (0.762mm) thick; and the elongate sleeves 100 are about 2 Mil (50.8micron) to about 12 Mil (304.8micron) thick but preferably about 4 Mil (101.6 micron) to about 8 Mil (203.2micron) thick.
In another embodiment of the bioreactor 500 shown in FIG. 7 the sleeve member 100 is comprising, in addition to an upper 14 and a lower 12 flexible sheet portion, a middle detachable filter sheet portion 16 adapted to dewater the algal medium and retain a thin layer of biomass body above the filter sheet 16 when ends or bottom of said sleeve CA 02836217 203.3-12-13 lower sheet portion 12 is opened, enabling fluid contained in the sleeve member 100 to escape and, or be recycled.
In yet another embodiment of the sleeve member 100, the sleeve member has a middle filter sheet portion 16 adapted to be disconnected from the sleeve upper 14 and lower sheet portions 12 and can be carried away by a conveyor belt into a heating zone able to dry and transform said biomass into thin peelable biomass crust.
In an embodiment of the multilevel photobioreactor 500 shown in FIG. 5, a biomass dewatering system 400 is further provided. The dewatering system 400 is comprising an elongate motorized conveyor belt located in a trough 420 that is positioned at the lowest level of bioreactor 500; the belt of the conveyor also functions as a filter 16 adapted to receive and partially dewater biomass. Filter / belt 16 is being exposed to a heating zone that dries and transforms the thin layer of biomass into a peelable crust collected by gravity.
Bioreactors 500 of the inventions have tightly stretched shelves 82 or panels 84 that may support one or two lines of elongate sleeve members 100. When two lines of sleeve members are laid on shelves 82 or on panels 84, a central support system 64 is being provided.
While some embodiments of bioreactor 500 are adapted to operate indoor, inside a warehouse, a shipping container 600 (see FIG. 9) or inside any other closed structure or building; other embodiments of bioreactor 500 are configured to operate outdoor, protected from weather conditions under structures such a greenhouse 1000 or an inflatable structure. In such a configuration, the elongate bioreactor 500 is located at the center of the tunnel-shape greenhouse 1000 with the cover being adapted to provide optimum photosynthetically active radiation (PAR) within wavelengths ranging about 400nm to 700nm with about 95% light diffusion; the lower portion of the greenhouse 1000 is provided with a reflective portion 210 having a parabola-shape configuration. The reflective material 210 may be flexible or semi-rigid and is adapted to reflect incoming light towards sleeves 100.
In an embodiment of the invention (FIG. 5), replacement of disposable or re-usable bioreactor container means or sleeves 100 is made easy by providing a stand (not shown) holding multiple rollers 18; the stand is located at one end of bioreactor 500 for holding a supply of rolls 18 of flexible container means 100; pulling out, from one end of bioreactor 500 a container means portion 100 causes a supply of fresh container means portion 100 to be dispensed from a corresponding roll 18 located at the other end of bioreactor 500; thus an empty or partially dewatered container means portion 100 may be easily and readily (after dewatering) replaced by a fresh un-contaminated container means portion 100. Replacement of an older container means may take place because of damage, leakage, contamination, wear and tear, loss of clarity or as part of a processing step wherein biomass contained in the container means 100 may be collected and further processed.
As an example of a processing step, a dewatered container means portion 100 may be gradually pulled out of the bioreactor shelves 82, sealed and then separated into small packages; this guarantees avoidance of contact with air or other extemal sources of contamination. In a further step, the sealed packages may be safely transported, frozen or directly sold to consumers or to buyers.
CA 02836217 2013-12-3.3 The bioreactor of the present invention 500 provides a controlled environment in which multiple parallel or serial processes may occur within a container means 100 of bioreactor 500 itself or in association with equipment and accessories that are in air or fluid communication with container means 100 or are introduced in said container means 100. As an example, in the present invention internal layers of said container means 100 may function as filtering membranes 16 having their own sparger tubes 22, 24 with holes 17 along their full length. When dealing with fluids of different densities, intemal layers may transfer or filter fluids via osmosis or reverse osmosis.
In another example, introducing venturi jets into the algal medium creates micro bubbles that separate solids from liquids and lift agglomerated cells to the fluid surface making harvesting of microalgae easy as a simple skimming process. Other processing steps within the bioreactor container means 100 may include electro flocculation, bioflocculation, blofloatation, fermentation, lysing, hydrogenation, localized heat treatment, localized light flash treatment, localized high or low magnetic field treatment;
some of said processes causing stresses that may increase biomass productivity or influence it; yet another example include oil extraction by fracturing cells walls with cavitational micro-bubbles, and a combination of multiple processes mentioned before.
The multilevel photobioreactor 500 is best made of at least one of the materials selected from the group consisting of: fiber reinforced plastic, low density polyethylene, high-density polyethylene, nylon, hard acrylic, polyvinyl chloride, polycarbonate, composite plastic, ethylene vinyl acetate, fiber glass, woven fabrics, non-woven fabrics and a combination thereof.
In an embodiment of the photobioreactor 500, the modular bioreactor 500 is encased and installed in a steel structure such as a shipping container 600; grouping multiple shipping containers 600 together scales-up fast installation of bioreactor 500.
In yet another embodiment of invention 500 shown in FIG. 6, thermal control of the bioreactor 500 is provided by circulating a cooling or heating fluid 40 in a water jacket 20; the water jacket 20 is created by positioning an elongate bag 120 longitudinally just below panels 84 and above a surface created by a repeating number of modular supports 86. Supports 86 are simply made by doubling panels 84 with a slight difference.
While they share same two opposite borders and respective holding attachments for tightening them, upper panels 84 are tightly stretched while lower panels 86 are loosely stretched and secured to opposite rack uprights 62; the upper tightly stretched panel 84 is sized to be of slightly shorter length that of the lower loosely stretched panel 86; in such an arrangement, lower loosely stretched panels 86 form collectively an elongate surface 88 over which may be extended a long flexible or semi-rigid shallow chamber or jacket 20. Circulating a slightly pressurized hot or cold fluid 40 in said shallow chamber 20 causes chamber 20 to press upwardly against the bottom of the upper tightly stretched panel 84 and exchange its heat or cold with bioreactor sleeve 100.
Depth of said shallow chamber 20 may vary between about 10mm to about 50mm at its lowest point.
In another embodiment of the invention, cooling of bioreactor 600 is achieved by evaporating dew very slowly seeping out from bioreactor container means upper wall 14.
To optimize cooling by evaporation, the container means 100 is having, preferably a top wail 14, a bottom wall 12, or both walls 12, 14 made of a transparent waterproof material that is breathable to enable very slow evaporation of condensates under a warm climate.
To expand inoculum gradually, controllably and safely without being exposed to contamination, mainly during traditional transfer of medium to larger containers has been a challenge among algae farmers. To overcome this challenge, the present bioreactor 500 provides an external movable divider 310 that enables a full volume of medium 42 contained in each of the container means 100 to be divided, then isolated and then expanded in a controlled manner; control of expansion being achieved by simple rolling or sliding one or multiple movable dividers 310 that are positionable under walls 12 and 14 of the flexible container means 100; said dividers 310 elevating and isolating a portion of said container means 100 include, but not limited to, movable rollers 310, liftable bars, roller-over-bars, stretchable bungees, ropes, cables, raisable panels, slidable self-standing dividers and a combination thereof.
To channel and collect water from spills or leakage from the bioreactor container means 100, a waterproof sheet positioned at the lowest level of the bioreactor 500 is provided with elongate borders being loosely stretched between the bioreactor opposite rack uprights 62; said waterproof sheet is further provided with a drainage means connected to hoses that carry water spills away.
The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.
Claims (37)
1. A multilevel photobioreactor comprising:
a modular racking system including upright frames and horizontal beams;
multiple, height-adjustable levels of transparent, thin, horizontal panels;
wherein adjacent panels at a same level forming collectively at least one elongate modularly extendable flat shelf; each panel comprising of a semi-rigid transparent sheet having two opposite borders tightly stretched between said rack uprights;
multiple removable flexible transparent container means, each adapted to lay longitudinally over said shelves and having at least on one side, an elongate wall portion adapted for being removably securable to a support means affixed to borders of an upper adjacent shelf;
each said container means adapted for biomass production therewithin.
a modular racking system including upright frames and horizontal beams;
multiple, height-adjustable levels of transparent, thin, horizontal panels;
wherein adjacent panels at a same level forming collectively at least one elongate modularly extendable flat shelf; each panel comprising of a semi-rigid transparent sheet having two opposite borders tightly stretched between said rack uprights;
multiple removable flexible transparent container means, each adapted to lay longitudinally over said shelves and having at least on one side, an elongate wall portion adapted for being removably securable to a support means affixed to borders of an upper adjacent shelf;
each said container means adapted for biomass production therewithin.
2. The multilevel photobioreactor of claim 1, wherein said container means comprising an elongate flexible transparent sleeve member.
3. The multilevel photobioreactor of claim 1, wherein said container means comprising an elongate sleeve member formed from a top and a bottom flexible transparent film having opposite longitudinal borders being sealed.
4. The multilevel photobioreactor of claim 1, wherein said container means comprising an elongate sleeve member formed from a top transparent portion, a middle filter portion and a bottom film portion having collective longitudinal borders being sealed.
5. The multilevel photobioreactor of claims 1 to 4, wherein bottom portion of said sleeve member incorporates at least one gas sparger tube for dispensing gases in the sleeve member.
6. The multilevel photobioreactor of claim 5, wherein each said sparger tubes is created by respectively folding, perforating and sealing a sleeve member portion along the sleeve member full length.
7. The multilevel photobioreactor of claims 5 and 6, wherein gases alternately pressurized between two of said sparger tubes, create, in a fluid contained in said sleeve member, a harmonic agitation along the full length of said sleeve member;
thereby creating waves and mixing intimately gases with the fluid.
thereby creating waves and mixing intimately gases with the fluid.
8. The multilevel photobioreactor of claims 1, 2, 3 and 4 wherein agitation along said sleeve members is achieved by generating vibrations along said sparger tubes;
said vibrations created by controllably varying volume and pressure of gases supplied in each of said sparger tubes using means such as, but not limited to, diaphragms, unbalanced or balanced rotors, unbalanced or balanced propellors, water-hammer generator, electrical modulation of air supply and a combination thereof.
said vibrations created by controllably varying volume and pressure of gases supplied in each of said sparger tubes using means such as, but not limited to, diaphragms, unbalanced or balanced rotors, unbalanced or balanced propellors, water-hammer generator, electrical modulation of air supply and a combination thereof.
9. The multilevel photobioreactor of claim 1, wherein said container means having a wall portion adapted to be removably securable to an elevated support means comprises a fold encasing a filler means including, but not limited to, a foam rope, a plastic rope, a jute rope, a cotton rope or a combination thereof; said elevated support means including a railing.
10. The multilevel photobioreactor of claims 1 to 9, wherein said elevated support means is adapted for said combination filler and fold portion to be squeezingly or slidingly engageable in said railing or for being slidingly or disengagibly retrievable therefrom; thereby making installation, retrieving and maintenance of sleeve members easy.
11. The multilevel photobioreactor of claim 1, further including an artificial light source means positionable under, above or on the side of said sleeve members or in a combination of said positions; said light source including, but not limited to, multiple parallel rows of light emitting diodes LED, each of selectable wavelengths being embedded, sandwiched or laminated between two transparent films forming collectively a wide flexible modular transparent mat electrically interconnectable.
12. The multilevel photobioreactor of claims 1, 10 and 11, wherein said light source means comprising sunlight, artificial light such as from light emitting diodes (LED) or a combination thereof.
13. The multilevel photobioreactor of claim 1, wherein longitudinal ends of said sleeve members are provided with fastenable fluid exit means that are positionable over at least one aperture present in said panels supporting said same sleeve members for enabling overflow from a higher sleeve member to one or multiple lower sleeve members.
14. The multilevel photobioreactor of claim 1, wherein said sleeve members longitudinal ends are adapted to receive one or multiple height-adjustable fluid exit means to control level of overflow from an upper sleeve member to a lower sleeve member.
15. The multilevel photobioreactor of claim 1, wherein a fluid contained in any of said sleeve members positioned at a higher level may flow or controllably overflow by gravity force to one or multiple sleeve members positioned at lower levels.
16. The multilevel photobioreactor of claims 1, 14 and 15, wherein a fluid contained within each of said sleeve members may exit in a vertical downward direction, in a horizontal sideway direction from right to left or vice-versa, or in a combination of directions thereof following a manually set pattern or following a pattern programmable by a controller means.
176. The multilevel photobioreactor of claim 1, further including an electrical coil system generating a magnetic field around selected or all said sleeve members;
said coil system also positionable at selected portions of sleeve members including, but not limited to, at said fluid exit means; thereby enhancing algal productivity.
said coil system also positionable at selected portions of sleeve members including, but not limited to, at said fluid exit means; thereby enhancing algal productivity.
18. The multilevel photobioreactor of claim 1, wherein accumulated weight resulting from scaling vertically the number of upper sleeve members in said bioreactor is transferrable to said upright frames and beams without affecting weight or water pressure on lower sleeves members.
19. The multilevel photobioreactor of claim 1, wherein biofilm or deposits from sedimentation within said sleeve members is removable by displacing a movable cleaning pig therewithin manually, automatically, by pressure differential means or by a combination thereof.
20. The multilevel photobioreactor of claim 1, wherein removal of oxygen from said sleeve members is achieved by inserting vent pipes in an upper portion of said sleeve members.
21. The multilevel photobioreactor of claim 1, wherein said sleeve members are composed of a transparent material allowing only photosynthetically active radiation (PAR) wavelengths of about 400 nm to 700 nm to reach an algal medium contained in said sleeve members.
22. The multilevel photobioreactor of claim 1, wherein dimensions of said modular racking systems are about 1.6 feet (0.5m) to about 13 feet (4m) wide, but preferably about 4 feet (1.2m) to about 8 feet (2,4m) wide; are about 1 feet (30cm) to about 20 feet (6m) high but preferably about 8 feet (2.4m) to about 12 feet (3.6m) high; and are about 4 feet (1.2m) to about 328 feet (100m) long but are preferably about 8 feet (2.4m) to about 164 feet (50m) long.
23. The multilevel photobioreactor of claim 1, wherein said photobioreactor has about 2 to about 40 shelf levels of, but preferably about 20 to 30 shelf levels; each said panels are about 0.010" (0.254mm) to about 0.080" (2.032mm) thick, but preferably about 0.02" (0.508mm) to about 0.03" (0.762mm) thick; and said elongate sleeve members are about 2 Mil (50.8micron) to about 12 Mil (304.8micron) thick but preferably about 4 Mil (101.6 micron) to about 6 Mil (203.2micron) thick.
24. The multilevel photobioreactor of claim 1, wherein selected elongate sleeve members comprising an upper and a lower sheet layer further including a middle filter membrane layer adapted to dewater said biomass and retain a thin layer of biomass body above said filter membrane layer; said dewatering provided when ends or bottom of said sleeve member lower layer are being opened to cause fluid contained above and below said filter layer to exit.
25. The multilevel photobioreactor of claim 24, wherein selected sleeve members having a middle filter membrane layer are adapted for said middle filter membrane layers to be separated from said upper and lower sheet portions and be carried away into a heating zone for drying and transforming said biomass into a thin peelable biomass crust; means for separating said filter membrane layer including, but not limited to, cutting open the collective opposite borders of said three-layered sleeve member for separating the middle filter membrane layer from the two other layers.
26. The multilevel photobioreactor of claim 1, further including an elongate trough positionable under lowest level of said shelves, said trough encasing a motorized conveyor belt acting as filter adapted to partially dewater biomass.
27. The multilevel photobioreactor of claim 26, wherein said dewatered biomass is further exposed to a heating zone able to dry and transform said biomass into a thin peelable biomass crust.
28. The multilevel photobioreactor of claim 1, further including an elongate greenhouse structure positionable around said bioreactor; said greenhouse structure having an upper translucent cover portion extending up to mid-height elevation and a lower reflective portion fastened to said upper portion; said upper cover portion being adapted to provide optimum light transmission of photosynthetically active radiation (PAR) within wavelengths ranging from about 400nm to about 700nm with optimum light diffusion; said lower reflective portion having a parabola-shape configuration made of a material adapted to reflect light towards said sleeves.
29. The multilevel photobioreactor of claim 1, further comprising a stand for supporting multiple rolls of said flexible container means; said stand positionable at one end of the bioreactor; pulling a used section of container means from one end of the bioreactor causes a new section of container means to unroll and position itself over a selected shelf; thereby making replacement of container means easy.
30. The multilevel photobioreactor of claims 1 to 29, wherein a container means portion containing diluted or dewatered biomass may be continuously pulled out of said bioreactor and heat sealed forming packages of biomass; thereby avoiding contact with air and other external sources of contamination.
31. The multilevel photobioreactor of claim 1, further including equipment and accessories in fluid communication with said container means for further processing biomass contained in said sleeve members; said processes and equipment including, but not limited to, filtering membranes, osmosis membranes, reverse osmosis membranes, venturi jets, harvesting , skimmers, means for dewatering, flocculation, electro flocculation, bioflocculation, biofloatation, fermentation, lysing, hydrogenation, localized heat treatment, localized light flash treatment, localized high magnetic field treatment, oil extraction, cavitation, and a combination thereof.
32. The multilevel photobioreactor of any one of claims 1 to 31, wherein at least one of said transparent flexible sheets, said filter sheets or said semi-rigid sheets, is made of a material selected from the group consisting of: fiber reinforced plastic, low density polyethylene, high-density polyethylene, nylon, hard acrylic, polyvinyl chloride, polycarbonate, composite plastic, ethylene vinyl acetate, fiber glass, woven fabrics, non-woven fabrics and a combination thereof.
33. The multilevel photobioreactor of claim 1, wherein said modular bioreactor is mounted inside one or multiple shipping containers.
34. The multilevel photobioreactor of claim 1, further including a water jacket functioning as thermal control in each of said sleeve members; said water jacket created by circulating a heating or a cooling fluid in a shallow chamber positionable on the underside of and pressing upwardly on said tightly stretched panels while resting over a flat surface created by loosely stretched panels that share the same two opposite borders of said upper tightly stretched panels; depth of said shallow chamber being determined by degree of looseness of said lower panels and substantially about 10mm to about 100mm at deepest point.
35. The multilevel photobioreactor of claim 1, wherein volume of medium contained in each of said container means may be divided, isolated and controllably expanded as per need; control of said expansion being achievable by moving one or multiple movable transversal dividers positioned under said container means walls; said dividers including, but not limited to, movable rollers, liftable bars, roller-over-bars, stretchable bungees, ropes, cables, raisable panels, self-standing dividers, slidable dividers and a combination thereof.
36. The multilevel photobioreactor of claim 1, wherein cooling of said container means is achieved by blowing air over a container means provided with a wall portion made of a waterproof but breathable material enabling slow evaporation of condensate under warm climate; said breathable portion including preferably said sleeve member top layer, but may also include said sleeve bottom layer, or may include both portions.
37. The multilevel photobioreactor of claim 1, wherein spills or leakage from any of said bioreactor container means may be collected into a waterproof sheet or containment means having elongate borders loosely stretched between said opposite rack uprights at any desired location in said bioreactor; said waterproof sheet being further attached to a drainage pipe or hose.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2836218A CA2836218A1 (en) | 2013-12-13 | 2013-12-13 | Multilevel photobioreactor |
| PCT/IB2014/003187 WO2015087169A2 (en) | 2013-12-13 | 2014-12-15 | Bioreactors supported within a rack framework and methods of cultivating microorganisms therein |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2836218A CA2836218A1 (en) | 2013-12-13 | 2013-12-13 | Multilevel photobioreactor |
Publications (1)
| Publication Number | Publication Date |
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| CA2836218A1 true CA2836218A1 (en) | 2015-06-13 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2836218A Abandoned CA2836218A1 (en) | 2013-12-13 | 2013-12-13 | Multilevel photobioreactor |
Country Status (2)
| Country | Link |
|---|---|
| CA (1) | CA2836218A1 (en) |
| WO (1) | WO2015087169A2 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109439522A (en) * | 2018-10-16 | 2019-03-08 | 厦门昶科生物工程有限公司 | A kind of efficiently photosynthetic culture spirulina Photoreactor |
| EP3845627A1 (en) * | 2019-12-31 | 2021-07-07 | Pall Corporation | Biocontainer assembly for bioprocessing system |
Families Citing this family (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2017019984A1 (en) | 2015-07-29 | 2017-02-02 | Avespa Holdings, Llc | Light emitting diode photobioreactors and methods of use |
| CN107429211A (en) * | 2015-08-14 | 2017-12-01 | 国家开发投资公司 | Stacked thin plate bioreactor |
| CN109321468A (en) * | 2018-12-12 | 2019-02-12 | 无棣鲁东大学海洋研究院 | The method and both culturing microalgae system of cultivating microalgae in a kind of region of ocean shoal |
| CN112849640B (en) * | 2020-12-28 | 2022-12-30 | 南京格利诺制药设备有限公司 | Support for supporting operation of pipeline type photobioreactor |
| EP4326845A1 (en) * | 2021-04-20 | 2024-02-28 | Algiecel ApS | Container and system for culturing phototrophic microorganisms |
| CN113512489A (en) * | 2021-07-08 | 2021-10-19 | 南京农业大学 | Flash illumination type microalgae biofilm reactor and microalgae culture method |
| DE102022100209B4 (en) | 2022-01-05 | 2024-03-14 | Solaga UG (haftungsbeschränkt) | Photobioreactor for preserving algae with externally illuminated compartments |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20070155006A1 (en) * | 2005-12-30 | 2007-07-05 | Alexander Levin | Photobioreactor |
| US8415142B2 (en) * | 2006-06-14 | 2013-04-09 | Malcolm Glen Kertz | Method and apparatus for CO2 sequestration |
| US8372632B2 (en) * | 2006-06-14 | 2013-02-12 | Malcolm Glen Kertz | Method and apparatus for CO2 sequestration |
| CN102224236A (en) * | 2008-11-12 | 2011-10-19 | 拉曼大学教育基金会 | A photobioreactor |
-
2013
- 2013-12-13 CA CA2836218A patent/CA2836218A1/en not_active Abandoned
-
2014
- 2014-12-15 WO PCT/IB2014/003187 patent/WO2015087169A2/en active Application Filing
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109439522A (en) * | 2018-10-16 | 2019-03-08 | 厦门昶科生物工程有限公司 | A kind of efficiently photosynthetic culture spirulina Photoreactor |
| EP3845627A1 (en) * | 2019-12-31 | 2021-07-07 | Pall Corporation | Biocontainer assembly for bioprocessing system |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2015087169A3 (en) | 2015-11-19 |
| WO2015087169A2 (en) | 2015-06-18 |
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