WO2013022670A1 - Photobioréacteurs flexibles, systèmes et procédés - Google Patents

Photobioréacteurs flexibles, systèmes et procédés Download PDF

Info

Publication number
WO2013022670A1
WO2013022670A1 PCT/US2012/049150 US2012049150W WO2013022670A1 WO 2013022670 A1 WO2013022670 A1 WO 2013022670A1 US 2012049150 W US2012049150 W US 2012049150W WO 2013022670 A1 WO2013022670 A1 WO 2013022670A1
Authority
WO
WIPO (PCT)
Prior art keywords
photobioreactor
channels
fluid distribution
culture medium
capsule
Prior art date
Application number
PCT/US2012/049150
Other languages
English (en)
Inventor
Kevin J. CALZIA
Max Brett TUTTMAN
John E. Longan
Thomas A. URBANIK
Original Assignee
Joule Unlimited Technologies, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Joule Unlimited Technologies, Inc. filed Critical Joule Unlimited Technologies, Inc.
Priority to US14/237,054 priority Critical patent/US20140186909A1/en
Publication of WO2013022670A1 publication Critical patent/WO2013022670A1/fr

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • 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
    • C12M21/00—Bioreactors or fermenters specially adapted for specific uses
    • C12M21/02—Photobioreactors
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • 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
    • C12M23/02—Form or structure of the vessel
    • C12M23/06—Tubular
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • 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
    • C12M23/26—Constructional details, e.g. recesses, hinges flexible
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • 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
    • C12M23/40—Manifolds; Distribution pieces

Definitions

  • microorganisms "Appl. Microbiol Biotechnol (2001) 57:287-293). These reactors have distinct advantages compared to open raceway bioreactors with respect to controlling temperature, pH, and nutrients, and limiting
  • One embodiment of the present invention is a photobioreactor, which includes a capsule with a top wall and a bottom wall.
  • the top wall and bottom wall are a flexible material (e.g. , a thin polymer film) and the top wall is at least partially composed of a material that is at least partially transparent to light of a wavelength that is photosynthetically active in a phototrophic microorganism.
  • a plurality of (e.g., two or more, three or more, five or more, eight or more) adjacent channels for enclosing microorganisms and culture medium are provided by sealing the top wall to the bottom wall to form seams.
  • each of the plurality of channels has a lay flat width between about 1 mm and about 2 m, more specifically, between about IS mm and about 1 m or, yet more specifically, between about 10 mm and about 100 mm.
  • the capsule further includes a fluid distribution structure coupled to the plurality of adjacent channels adapted for fluid communication with the plurality of adjacent channels that distributes a flow of culture medium amongst the plurality of adjacent channels, wherein the fluid distribution structure is comprised of a flexible polymer film.
  • the seams can be formed by welding or heat sealing the top wall to the bottom wall.
  • Each channel when filled with microorganisms and culture medium, can have a substantially semi-circular, substantially circular, or substantially elliptical cross-section.
  • the top wall and bottom wall can be made of a polymer or a polymer-composite film.
  • the plurality of adjacent channels can have a length of about 100 meters and a width of about 1 meter. Alternatively, the plurality of adjacent channels of the photobioreactor can have a length of about 10 m to about 300 m.
  • the capsule can have four or more channels for enclosing a phototrophic microorganism and culture medium therefor.
  • a substantially even depth of microorganisms and culture medium can be provided across the channels and averages between about 5 mm and about 30 mm, between about 10 mm and about 30 mm, or between about 20 mm and about 30 mm.
  • the bottom wall can be an abrasion resistant material.
  • the plurality of channels can be of a thin-wall construction that couples to a circulation driver producing a flow of the microorganisms and culture medium through the channels.
  • Another embodiment of the invention is a photobioreactor for a
  • phototrophic microorganism, and culture medium therefor comprising a capsule comprising an elongated body having a length and a width and comprised of a flexible polymer film that is at least partially transparent to light of a wavelength that is photosynthetically active in a phototrophic microorganism, wherein the elongated body is divided widthwise into a plurality of adjacent channels, each having its major cross-sectional dimension that is not more than about one-third of the length of the elongated body, when the elongated body is inflated; and a fluid distribution structure coupled to the elongated body adapted for fluid communication with the plurality of adjacent channels that distributes a flow of culture medium amongst the plurality of channels.
  • Another embodiment of the invention is a photobioreactor for a
  • phototrophic microorganism, and culture medium therefor comprising a capsule comprising a plurality of adjacent channels, each of the plurality of adjacent channels having an inflow end and an outflow end, the plurality of channels being in a substantially planar arrangement and being formed by bonding two or more polymer films collinearly and lengthwise in a flow direction, the bonding providing bonded seams; a fluid distribution channel formed across the inflow end of the plurality of channels and substantially perpendicularly to the flow direction, the fluid distribution channel having a fluid inlet at an end of the fluid distribution channel, being in fluid communication with the plurality of channels, being adapted to distribute a flow of culture medium amongst the plurality of channels, and being formed by a polymer film; and a fluid collection channel formed across the outflow end of the plurality of channels and perpendicularly to the flow direction, the fluid collection channel having a fluid outlet at an end of the fluid collection channel, being in fluid
  • Another embodiment of the invention is a method of cultuiing a phototrophic microorganism using aphotobioreactor or capsule of the invention.
  • Another embodiment of the invention is a method of producing a
  • the photobioreactor capsules disclosed herein can maintain an
  • the depth of the culture medium can be decreased and the ratio of the major surface area to the culture depth can be increased, providing for increased photon absorption.
  • the fluid distribution structures disclosed herein are adapted to reduce hoop stress or load on a capsule film or seams, thereby increasing the factor of safety of the capsules and/or enabling the capsules to be used under more challenging conditions, such as higher pressures and/or flow rates, with a decreased incidence of failure.
  • FIG. 1 is a perspective view of and illustrates a capsule constructed in accordance with an exemplary embodiment of the invention.
  • FIG. 2A is a top profile view diagram illustrating a capsule constructed in accordance with an exemplary embodiment of the invention.
  • FIG. 2B is a cross-sectional diagram along line A in FIG. 2A and
  • FIGS. 3 A, 3B, and 3C are top profile view diagrams and illustrate exemplary fluid distribution structures coupled to elongated bodies (not shown in full) and constructed in accordance with exemplary embodiments of the invention.
  • FIGS. 4A, 4B, 4C, 4D, 4E, 4F, and 4G are top profile view diagrams and illustrate exemplary fluid distribution structures coupled to elongated bodies (not shown in full) and constructed in accordance with exemplary embodiments of the invention.
  • FIGS. 5A, SB, and 5C are top profile view diagrams and illustrate exemplary fluid distribution structures coupled to elongated bodies (not shown in full) and constructed in accordance with exemplary embodiments of the invention.
  • FIG. 5D is a top profile diagram and illustrated an exemplary capsule constructed in accordance with exemplary embodiments of the invention.
  • FIG. 6 is a graph and shows the calculated hoop stresses associated with various channel diameters of an unrestrained 6mil film capsule as a function of internal pressure.
  • FIGS. 7A and 7B are cross-sectional diagrams and illustrate a thin-film capsule inflated (FIG. 7A) and deflated (FIG. 7B).
  • FIG. 8 is a schematic diagram and shows a photobioreactor including an external pressure plate constraining a fluid distribution structure coupled to an elongated body (not shown in full).
  • FIG. 9 is a schematic diagram and illustrates a top plate and a bottom plate of a pressure plate from several perspectives.
  • FIG. 10 is a diagram and illustrates a 22-channel capsule having an integrated header.
  • FIG. 11 is a bar graph and shows the average calculated channel flow velocity in a capsule of FIG. 10 having a header diameter of 50mm, 75mm or 100mm as a function of channel number (channels were numbered starting with the channel nearest the fluid inlet).
  • FIG. 12 is a schematic diagram and shows an exemplary C-tube
  • microorganisms refers to a single element of stated alternative elements or a combination of two or more elements, unless the context clearly indicates otherwise.
  • a first embodiment of the invention is a photobioreactor for a
  • phototrophic microorganism, and culture medium therefor comprising a capsule, the capsule comprising an elongated body having a length and a width and comprised of a first, flexible polymer film that is at least partially transparent to light of a wavelength that is photosynthetically active in a phototrophic microorganism, wherein the elongated body is divided widthwise into a plurality of adjacent channels, each having a major cross-sectional dimension that is not more than about one-third of the length of the elongated body, when the elongated body is inflated; and a fluid distribution structure coupled to the elongated body adapted for fluid communication with the plurality of adjacent channels mat distributes a flow of culture medium amongst the plurality of channels, wherein the fluid distribution structure is comprised of a second, flexible polymer film.
  • each of the plurality of adjacent channels is substantially equivalent to every other channel.
  • the first flexible polymer film and the second flexible polymer film are the same.
  • FIG. 1 is a perspective view of an exemplary capsule of the invention.
  • Capsule 102 includes channels 106 of the elongated body coupled to inlet 116 via fluid distribution structure 120. Channels 106 are also coupled to outlet 118 via fluid distribution structure 122.
  • fluid distribution structures 120 and 122 are mirror images of one another (e.g., photobioreactor 102 is symmetrical around axis S). In other embodiments, fluid distribution structures 120 and 122 are not mirror images of one another ⁇ e.g.,
  • photobioreactor 102 is not symmetrical around axis S).
  • a second embodiment of the invention is a capsule comprising an elongated body comprising a first, flexible top wall composed at least partially of a material that is at least partially transparent to light of a wavelength that is photosynthetically active in a phototrophic microorganism, and a first, flexible bottom wall, wherein two or more channels for enclosing the phototrophic microorganism and culture medium therefor are provided by coupling the top wall to the bottom wall with a laying flat width of each two or more channels between about 15 mm and about 1 m; and a fluid distribution structure including a second, flexible top wall coupled to the first, flexible top wall and a second, flexible bottom wall coupled to the first, flexible bottom wall.
  • a third embodiment of the invention is a capsule, the capsule
  • a fluid distribution structure including a second top wall coupled to the first top wall and a second bottom wall coupled to the first bottom wall, wherein the first and second top walls are formed from a first single piece of a flexible polymer composite film and the first and second bottom walls are formed from a second single piece of the flexible polymer composite film, the flexible polymer composite film is at least partially transparent to light of a wavelength that is photosynthetically active in a phototrophic microorganism, and each channel has a major cross-sectional dimension of between about 25 mm and about 50 mm, inclusive.
  • the top and bottom walls of the elongated body are sealed lengthwise at even intervals to form two or more evenly spaced seams.
  • .channels 206A-D are formed by seams 214 welded lengthwise between top sheet 208 and bottom sheet 210.
  • Seams can be produced using a variety of known welding techniques, for example, conductive, laser, microwave, ultrasonic weld, or chemical welding devices and methods. Polymer melts or reactive chemistry can also be used to form seals. Other materials can be used to seal the top and bottom sheets to form seams, for example, adhesives (e.g., extruded adhesives), laminates or fasteners (e.g., an external clamshell).
  • the phototrophic microorganism contained in the photobioreactor capsules of the invention require light for growth and/or the production of carbon-based products of interest. Therefore, the capsules and, in particular, channels 206A-D in FIGS. 2A and 2B are adapted to be at least partially composed of a material that is at least partially transparent to light of a wavelength that is photosynthetically active in the phototrophic microorganism.
  • an elongated body including a top wall composed of a flexible polymer film at least partially transparent to light of a wavelength that is photosynthetically active in a phototrophic microorganism and a bottom wall, wherein the top and bottom wall are sealed lengthwise to form one or more seams that form the plurality of channels in the elongated body.
  • the top wall and the bottom wall of the elongated body are both composed of the same flexible polymer film.
  • FIG. 2A is a top profile diagram of an exemplary capsule of the
  • FIG. 2B is a cross-sectional diagram along line A of the capsule depicted in FIG. 2A.
  • Capsule 202 is provided by a thin-film, flexible polymeric material. In the capsule depicted in FIGS. 2A and 2B, capsule 202 is formed by welding top sheet 208 and bottom sheet 201 lengthwise along both outside edges 212 to form seams.
  • Capsule 202 includes a plurality of channels (206A, 206B, 206C, and 206D) and is adapted to allow cultivation in culture medium of a phototrophic microorganism. [0037] Phototrophic microorganisms growing in photobioreactors can be suspended or immobilized.
  • the average depth of the layer of culture medium is between about S mm and about 30 mm, between about 10 mm and about IS mm or, preferably, between about 10 mm and 30 mm or between about 20 mm and about 30 mm.
  • a desired depth of the layer of phototrophic microorganisms can be achieved.
  • a substantially even layer can have various depths ranging from about 5 mm to about 30 mm for a substantial surface area portion of the layer, or from about 10 mm to about IS mm.
  • a capsule can include blown films that are
  • the blown films can have the shape of multiple channels or include individual channels of blown films sealed together.
  • the sealing can be provided by using a variety of known welding techniques, for example, conductive, laser, microwave, ultrasonic weld, or chemical welding devices and methods.
  • Top sheet 208 need not include structural support elements.
  • the internal pressure within capsule 202 supports top sheet 208 above the culture medium and microorganisms.
  • Top sheet 208 can be collapsed onto bottom sheet 210 when the culture medium, microorganisms and gases are removed from capsule 202.
  • Capsule 202 is not limited to four channels and can have as many or as few as desired according to the intended design constraints of capsule 202. These design constraints can include, for example, the major cross-sectional dimension of each channel, end region geometry, total width of the capsule, flow characteristics, mechanical stress on the capsule, and/or other design constraints. These design constraints can include, for example, the major cross-sectional dimension of each channel, end region geometry, total width of the capsule, flow characteristics, mechanical stress on the capsule, and/or other design constraints.
  • Channels 206A-D are also not limited to a straight path as shown in FIGS. 1, 2A and 2B. Embodiments can utilize curved seams 214 that produce winding paths or channels with varying widths.
  • Channels 206A-D can also be a variety of different shapes and sizes. Each channel 206A-D of aphotobioreactor can be of a different shape and dimension. Typically, however, in capsule 202 with a plurality of channels 206A-D, the channels are substantially equivalent (e.g., produce similar or identical amounts of the microorganism, produce similar or identical amounts of a carbon-based product, support similar or identical flow rates, support similar or identical culture depths, are of similar or identical shape and dimensions, or a
  • capsule cross-sections are suitable, for example, substantially circular or half-elliptical.
  • the capsule cross- section is substantially half-elliptical or rectangular.
  • the capsule is not limited to both top and bottom sheets being of flexible material.
  • the bottom sheet can be a relatively rigid material sealed to a top sheet of a flexible material along the edges and lengthwise to form seams, as previously described, that form channels.
  • the capsule can be enclosures (e.g., bags) welded from thin polymeric films.
  • Top sheet 208 can be transparent for light of a wavelength that is photosynthetically active in a phototrophic microorganism. This can be achieved by proper choice of the material, for example, thin-film material for top sheet 208 to allow light to enter the interior capsule.
  • Bottom sheet 210 can be provided by a thin-film material enclosure, typically made from a polymeric material with abrasion resistance. In applications in which bottom sheet 210 rests directly on the ground, the bottom sheet can include a polymeric material of greater thickness, multiple layers, and/or additional features that can prevent abrasions or tears due to contact with coarser material, such as, gravel, or other objects on the ground.
  • Bottom sheet 210 can also incorporate a reflective internal surface to allow light that has passed through capsule 202 to be reflected back through capsule 202 to allow the phototrophic microorganism to capture more light.
  • Embodiments can include top sheet 208 and bottom sheet 210 being encapsulated with additional independent top and bottom enclosures that provide the abrasion resistance and/or other characteristics that protect capsule 202 from the external environment while allowing passage of a wavelength of light for photosynthetic activity.
  • the top wall consists essentially of a first flexible polymer film and the first flexible polymer film has a thickness of less than 500 micrometers.
  • the predetermined amount can be designated by a specific pressure (e.g., an inlet pressure of greater than 0.5 psi, greater than 2.0 psi, greater than 4 psi, greater than 6 psi, or greater than 10 psi), volume or other unit
  • a specific pressure e.g., an inlet pressure of greater than 0.5 psi, greater than 2.0 psi, greater than 4 psi, greater than 6 psi, or greater than 10 psi
  • the predetermined amount is not limited to a specific quantity but can include algorithms and/or increments of various amounts including, but not limited to, sequential increases and/or decreases.
  • the capsule described herein can be placed on the ground or floated on water such that top sheet 208 is directed upwards and bottom sheet 210 can be placed on the ground or water.
  • the capsule(s) can also be placed above the ground and can utilize solid support structures made of, for example, wood, metal, mesh or fabric.
  • Other support structures can include, for example, stakes, anchors or cables attached to flaps along the edges of the capsule.
  • straps or loops are provided along both edges of the capsule. The straps or loops can be used in conjunction with stakes or anchors to secure the capsule to the ground or other surface.
  • the straps or loops can be of the same material as bottom sheet 210, or of another material.
  • the straps or loops can be molded into or adhered to seam 214 or coupled to holes provided in the center of seam 214 such that a seal is provided around the hole and within the seam.
  • the support structures can be used to prevent rotation or movement of the capsule.
  • the support structure can be used to prevent movement due to gravity, unintended external forces and/or inclement weather.
  • the photobioreactors can include, in addition to a capsule, a number of devices that can support the operation of the photobioreactors.
  • devices for flowing gases e.g., carbon dioxide, air, and/or other gases
  • measurement devices e.g., optical density meters, thermometers
  • inlets and outlets and other elements
  • Capsule 202 can include further elements (not shown) such as inlets and outlets, for example, for growth media, carbon sources (e.g., CO 2 ), and probe devices such as optical density measurement devices, thermostats, and thermometers.
  • capsule 202 can be adapted to allow gas flow through various channels 206A-D.
  • Gas (e.g., CO 2 ) flow can be co- or counterdirectional to liquid flow through the reactor.
  • the capsule is adapted to allow codirectional gas flow in one part of the capsule and counterdirectional gas flow in another part of the capsule.
  • one or more capsules in an array of capsules are adapted to allow codirectional gas flow, and one or more other capsules of the photobioreactor in an array of capsules are adapted to allow counterdirectional gas flow.
  • support straps or a sheet can be used to further allow for a desired shape of channels 206A-D.
  • the support straps can be strips of polymeric material or cords across the width of channels 206A-D. As channels 206A-D are inflated, the support straps can be brought into tension providing more of a rectangular shape with a desired major cross-sectional dimension to channels 206A-D.
  • the support straps or sheet can also be a mesh sheet or other sheet of material with various openings.
  • the support straps can be incorporated in the manufacturing of the capsule design by placing the straps or threads between top and bottom sheets 208, 210 of thin film of capsule 202.
  • the straps or threads can be coupled to the outer edges during an edge sealing process. The sealing process can weld or adhere the straps or threads between top and bottom sheets 208, 210.
  • a circulation driver can be used to provide a flow of culture medium in the capsules described herein.
  • Exemplary embodiments can utilize one or more circulation drivers and/or can comprise a single directional flow.
  • Circulation drivers are not limited to utilizing an induced circulation system.
  • gravity driven, tidal driven, air driven, thermally driven, or circulation systems that do not involve active contact with the material being circulated can also be used to provide circulation.
  • Exemplary circulating drivers can also utilize active circulation devices, such as pumps or augers, that actively apply a contact and apply a force to the circulating material.
  • Exemplary embodiments of capsules described herein can utilize a collapsible tube constructed of polymer film approximately 1 meter wide by 100 meters in length, when inflated.
  • the culture medium, microorganisms and gases can be introduced into a capsule via a port fitting at one end of the capsule and exit via a port fitting at the other end.
  • An internal pressure can be created by the culture medium, microorganisms and gases. If the pressure is sufficiently high and the flexible tubes of the capsule are left unrestrained, the pressure can cause the collapsible tubes of the capsule to inflate into a long tubular shape.
  • Each collapsible tube has a length and a major horizontal cross-sectional dimension. When the collapsible tubes are inflated, a major surface area of each tube can be calculated by multiplying the length by the major horizontal cross-sectional dimension.
  • horizontal is defined with respect to the surface which supports the capsule (e,g. , the ground, the water).
  • each channel when inflated with air at atmospheric pressure, can be semi-circular, of a short and wide rectangle, or elliptical. Also typically, depending on the fill level with culture medium and gas, operating pressure, and support for the flexible elongated body of the photobioreactor, the cross- sectional shape varies.
  • elongated body refers to a body having a length, a width, and a height, wherein the length is substantially greater than the width, and the width is substantially greater than the height when the body is inflated.
  • the length is at least 3, at least 10, at least 50, about 100, or at least 100 times greater than the width.
  • the width is about 100, at least 100, about 40, about 20, or about 10 times greater man the height.
  • the length is about 100 times greater than the width, and the width is about 20 times greater than the height.
  • the length is about 10 to about 300 m, about 100 to about 300 m, about SO to about 100 m, or about 100 m.
  • the width is about 1 and about 2 m or about 1 and about 1.5 m.
  • the height is about 10 to about 100 mm, about 30 to about 55 mm, about 40 to about 55 mm, or about 45 mm.
  • the length is about 100 m, the width is about 1 m, and the height is about 45 mm.
  • the elongated body has a length of about 100 to about 300 m, a width of about 1 to about 2 m, and a height of about 40 to about 55 mm.
  • the length of the elongated body is at least 50 m and the height of each channel is between about 10 mm and 100 mm.
  • any combination of a length, a width, and a height recited above is possible.
  • the elongated body is rectangular. In other embodiments, each of the plurality of adjacent channels of the elongated body are substantially equivalent or, more specifically, are of similar or identical shape and dimensions. In yet other embodiments, the elongated body is rectangular and each of the plurality of adjacent channels of the elongated body are substantially equivalent or, more specifically, are of similar or identical shape and dimensions.
  • the flexible polymer film that forms the capsule, elongated body, and/or fluid distribution structure can be a homopolymer, copolymer or even a multi-layered composite polymer based film.
  • aphotobioreactor capsule can also be composed of a multi-layer film composed predominately of polyethylene and nylon.
  • the photobioreactor capsule can be fabricated from two, separate multi-layer films that are laminated together and can be represented as
  • One of the starting films is made via lamination from cast film and the other starting film is made via a co-extrusion blown film process.
  • the film structure showing the composition of the two starting films can be represented as:
  • PE polyethylene
  • PA polyamide
  • tie refers to a thin ⁇ e.g. , less than about 5 microns) layer of a polymeric material used to join dissimilar polymers (e,g, polyethylene and polyamide or nylon).
  • a tie layer contains chemical functionality that will react with one of the dissimilar polymers to form chemical bonds and is miscible with the other dissimilar polymer so there is entanglement of the polymer chains.
  • the tie layer is a co-polymer of ethylene and maleic anhydride.
  • seals can be formed by a pressure plate (e.g., an external clamshell) that exerts adequate force on the flexible walls of the chamber to create a fluid-tight seal.
  • a pressure plate can also be used to reinforce, for example, a portion of a welded seal (e.g., an end of the welded seal).
  • Another embodiment of the invention is a capsule comprising a
  • each of the plurality of adjacent channels having an inflow end and an outflow end
  • the plurality of channels being in a substantially planar arrangement and provided by two or more polymer films bonded collinearly and lengthwise in a flow direction a fluid distribution channel formed across the inflow end of the plurality of channels and substantially perpendicularly to an intended flow direction, the fluid distribution channel having a fluid inlet at an end of the fluid distribution channel, being coupled to the plurality of adjacent channels, being adapted for fluid
  • the fluid collection channel formed across the outflow end of the plurality of adjacent channels and perpendicularly to the intended flow direction, the fluid collection channel having a fluid outlet at an end of the fluid collection channel, being coupled to the plurality of adjacent channels, being adapted for fluid communication with the plurality of adjacent channels, and being formed by a third polymer film, wherein the two or more polymer films are at least partially transparent to light of a wavelength that is
  • each channel is at least about 50 m
  • each channel has an inflated diameter between about 10 mm and about 100 mm, inclusive
  • the fluid distribution channel has an inflated diameter of about 50 mm and about 250 mm, inclusive.
  • each channel is at least about 50 m
  • each channel has an inflated diameter between about 25 mm and about 50 mm, inclusive
  • the fluid distribution channel has an inflated diameter of about 50 mm and about 125 mm, inclusive.
  • the present invention also provides a method of fabricating a
  • photobioreactor capsule the method comprising extruding a sheet of flexible polymer film to produce a first sheet of flexible polymer film and a. second sheet of flexible polymer film; and coupling the first sheet of flexible polymer film to the second sheet of flexible polymer film to form an elongated body comprising a plurality of adjacent channels and a fluid distribution structure.
  • the first sheet of flexible polymer film and the second sheet of flexible polymer film are the same and are a composite polymer film.
  • the method of fabrication further comprises forming a series of barriers within the fluid distribution structure by heat sealing the first sheet of flexible polymer film to the second sheet of flexible polymer film.
  • the first sheet of flexible polymer film is coupled to the second sheet of flexible polymer film by heat-sealing the first sheet of flexible polymer film to the second sheet of flexible polymer film or by an extruded sealing process.
  • Another embodiment is a photobioreactor capsule of the invention, formed by extruding a sheet of flexible polymer film to produce a first sheet of flexible polymer film and a second sheet of flexible polymer film, and coupling the first sheet of flexible polymer film to the second sheet of flexible polymer film to form the elongated body comprising the plurality of adjacent channels and the fluid distribution structure.
  • a fluid distribution structure can be in the form of an asymmetrical or symmetrical fluid distribution structure, an integrated header, or an in-line distribution region.
  • a fluid distribution structure can be designed to effect fluid
  • a fluid distribution structure can include one or more barriers to effect fluid distribution (as illustrated, for example, in FIGS. 3A-3C, 4A-4G, and 5A-5D).
  • the shape, for example the tapered shape, of the fluid distribution structure can also effect fluid distribution, (as illustrated, for example, in FIGS. 1, 3A-3C, 4A-4G, and 5A-5D).
  • a change in a dimension of a fluid distribution structure can also effect fluid distribution, as in the case of the integrated header depicted in FIG. 10, for example, in which the inflated diameter of the integrated header affects the distribution of the culture medium (see FIG. 11).
  • Fluid distribution can also be effected by any combination of the above designs.
  • the fluid distribution structures illustrated in FIGS. 3 A-3C, 4A-4G, and 5A-5D effect fluid distribution by including one or more barriers and by being tapered.
  • symmetrical fluid distribution structure means a region of a photobioreactor capsule designed to support distribution (preferably, even distribution) of a flow of culture medium amongst a plurality of channels using a symmetrical arrangement of barriers.
  • a barrier can be a seam formed in the interior of the fluid distribution structure of the capsule, such as the diamond depicted in FIG. 4E or the welded island depicted in FIG. 5D.
  • FIG. 10 illustrates an example of a 22-channel capsule of the invention with a fluid distribution structure in the form of an asymmetric integrated header 1032.
  • asymmetries in the header geometry may lead to unequal pressure drops along each flow path and thus uneven flow distribution. These pressure drops can be associated with the flow along the length of the header or with the transition from header to the channels. Flow traveling to channels furthest from the header inlet experience additional pressure drop along the length of the header, while flow traveling to the channels closest to the inlet undergo additional pressure drop associated with the sharp turn of high velocity flow.
  • integrated header means a region of a
  • Flow path is any one of several paths liquid can take through a photobioreactor capsule of the invention, (e.g., from the inlet to the fluid distribution structure through a particular channel to the outlet of the photobioreactor capsule).
  • An integrated header can be asymmetric (e.g., as shown in FIG. 10).
  • An integrated header can also be tapered (e.g., the inflated diameter at one end of an asymmetric integrated header is 4 inches and is 2 inches at another end of the asymmetric integrated header).
  • an integrated header includes one or more barriers.
  • an integrated header is barrier-free (i.e., without barriers within the integrated header).
  • the photobioreactor capsules of the invention include a fluid
  • the fluid distribution structure coupled to the plurality of adjacent channels or elongated body adapted for fluid communication with the plurality of adjacent channels that distributes a flow of culture medium amongst the plurality of adjacent channels.
  • the flow of culture medium in each of the plurality of channels in the photobioreactors of the invention is typically co-directional.
  • the fluid distribution structure includes one or more barriers (e.g., at least 3, at least 5, at least 10, or at least as many barriers as there are seams separating channels of the elongated body (for example, barriers that are an extensions of the respective channel seams)) that support distribution of and, preferably, evenly distributes, the flow of culture medium amongst the plurality of channels.
  • the fluid distribution structure includes a top wall and a bottom wall, and the barriers are provided by sealing a portion of the top wall to a portion of the bottom wall. In some embodiments, the fluid distribution structure includes a top wall and a bottom wall that are sealed to one another to form the fluid distribution structure.
  • the top wall of the elongated body and the top wall of the fluid distribution structure, together, are formed from a single piece or sheet of flexible polymer film, and the bottom wall of the elongated body and the bottom wall of the fluid distribution structure, together, are formed form a second, single piece or sheet of flexible polymer film.
  • the top wall of the elongated body is connected to the top wall of the fluid distribution structure and the bottom wall of the elongated body is connected to the bottom wall of the fluid distribution structure.
  • the top wall of the elongated body is sealed to the top wall of the fluid distribution structure and the bottom wall of the elongated body is sealed to the bottom wall of the fluid distribution structure.
  • Another method that can be used alone or in combination with the fluid distribution structure to create substantially uniform flow is to create breaks or stagger the channels along the length of the reactor channel. If the flow is not evenly distributed at the entrance to the channels, the breaks can be used to aid in re-distributing the flow further along the length of the capsule.
  • the width of the capsule decreases due to material being restrained in the channel seam. This can cause wrinkling and pinching of the film at the angled ends, possibly limiting flow of the culture or gases.
  • the channel geometries at the entrance and exit region can be optimized. Several possible methods of doing this are shown, for example, in FIGS. 3-5.
  • the channels can allow for substantial organism productivity, decreased stress in the film, continuous flow along the channels to supply gases and mixing, and/or allow for cleaning and sterilization of the capsule, among other advantages.
  • Distribution can be measured by comparing the volumetric flow of culture medium in a channel to the average flow of culture medium across all the channels.
  • the percent difference between a flow of culture medium in a channel and tile average flow of culture medium across all the channels is less than or equal to 50%.
  • there is substantially even distribution so that the percent difference between a flow of culture medium in a channel and the average flow of culture medium across all the channels is, for example, less than or equal to 20%, less than or equal to 10%, less than or equal to 5% or less than or equal to 1%.
  • FIGS. 3-5 are top-profile diagrams of various illustrative in-line fluid distribution structures coupled to elongated bodies (not shown in full) in accordance with the present invention. As used herein, "in-line fluid
  • distribution structure refers to a fluid distribution structure in which the direction of the fluid as it enters the fluid distribution structure is substantially the same as the direction of the fluid as it flows through the channels.
  • the distribution can be designed to provide a substantially even distribution between the channels or can be designed to favor flow to certain channels.
  • substantially even distribution allows for substantially even amounts to be dispersed to each of the channels.
  • dashed line 999 in FIGS. 2A, 3A-3C, 4A-4G, 5A-5D and 10 indicates the boundary between the elongated body and the fluid distribution structure.
  • FIGS. 3A, 3B, and 3C show exemplary 6-channel fluid distribution structures coupled to elongated bodies (not shown in full). Other embodiments have analogous barrier arrangements with fewer or more than six channels.
  • entrance port or inlet 316 feeds two or more channels formed by seams 314.
  • seams 314 between opposing ends provide six channels for enclosing microorganisms and culture medium.
  • Each of the five seams 314 is progressively shorter lengthwise from the center of the photobioreactor to each of the opposing edges 312.
  • seams 314 assist to disperse the flow from the center of entrance port 316.
  • the flow is initially dispersed into three sub-flows and subsequently the center sub-flow is further dispersed into two additional sub-flows, which are each subsequently dispersed into two additional channel flows in channels 306.
  • seams 314 provide alternating sequences of separated flows and un-separated flows. At each point of un-separated flow, the flow can be distributed into two or more sub-flows.
  • the liquid flow passes out of fluid transition region 320 and into channels 306 at point 318.
  • FIGS. 4A, 4B, 4C, 4D, 4E, 4F, and 4G show exemplary 8-channel distribution structures coupled to elongated bodies (not shown in full).
  • seams 414 split the liquid flow and distribute it amongst channels 406.
  • the liquid flow passes out of fluid transition region 420 and into channels 406 at point 418.
  • FIG. 4E utilizes void space 430 in the shape of a diamond to distribute the liquid flow through fluid distribution structure 420, past point 418 and into channels 406.
  • FIG. 4F uses a combination of void space 430 and seams 414 in fluid distribution structure 420 to distribute the liquid flow into channels 406.
  • FIG. 4F also utilizes separated and un-separated flows to distribute the liquid flow into channels 406.
  • FIG. 4G like FIG. 4F, employs both seams 414, and separated and un-separated flows to distribute the liquid flow into channels 406.
  • Void space 430 in FIGS. 4E and 4F is formed by a large welded space in the shape of a diamond. However, any shape may be used to form a void space. For example, a void space can be diamond-shaped, circular, oval-shaped or triangular. In addition, a void space may be formed by removing the excess material from the center of the welded area, as long as the integrity of the capsule is maintained.
  • FIGS. 5A, 5B, and SC show exemplary 22-channel distribution
  • FIG. 5D shows an exemplary 22-channel capsule.
  • FIGS. 5A and SB resemble FIG. 3B, but illustrate fluid distribution structures having more channels.
  • each seam 514 in FIGS. 5 A and 5B ends in a circular sealed portion that distributes the hoop stress around the circumference of seam end 522.
  • Bulges 518 in seams 514 in FIGS. 5 A and 5B indicate the position at which the transition region is sealed to channels 506 of the photobioreactor.
  • Fluid distribution structure 520 depicted in FIG. 5C utilizes seams 514 oriented perpendicularly to the fluid flow to distribute the liquid.
  • FIG. 5D shows fluid distribution structure 520 having oval-shaped void space 530 to distribute liquid into channels 506.
  • one aspect of the first to third embodiments of the invention is a fluid distribution structure coupled to the elongated body and adapted for fluid communication with the plurality of adjacent channels that evenly distributes a flow of culture medium amongst the plurality of channels, wherein the fluid distribution structure is comprised of a second, flexible polymer film, and includes a top wall and a bottom wall that are sealed to one another to form one or more barriers that support distribution of and, preferably, evenly distributes, the flow of culture medium amongst the plurality of channels.
  • the one or more barriers form a continuous extension of one or more of the seams into the fluid distribution structure. More specifically, the one or more barriers forming a continuous extension extend one or more of the seams of the elongated body linearly and lengthwise into the fluid distribution structure. Yet more specifically, there is a plurality of barriers and the plurality of barriers forming a continuous extension of the seams extends one or more of the seams linearly and lengthwise into the fluid distribution structure such that the channels become progressively shorter from a central channel(s) toward an outermost channel(s).
  • the plurality of barriers forming a continuous extension of the seams extend one or more of the seams linearly and lengthwise into the fluid distribution structure and are substantially parallel to one another and substantially parallel to the seams.
  • the plurality of barriers forming a continuous extension of the one or more seams extends one or more of the seams linearly and lengthwise into the fluid distribution structure and includes one or more barriers that are
  • the plurality of barriers include one or more central barriers that are substantially parallel to the seams and one or more flanking barriers that are angled towards the one or more central barriers.
  • the one or more barriers form a continuous and lengthwise extension of one or more of the seams into the fluid distribution structure. More specifically, the one or more barriers that form the continuous and lengthwise extension of one or more of the seams into the fluid distribution structure are curved, bent, or linear, or a combination thereof. Yet more specifically, a plurality of barriers form a continuous and lengthwise extension of one or more of the seams into the fluid distribution structure and the plurality of barriers includes one or more central barriers parallel to the seams and one or more flanking barriers curved, bent, or angled towards the one or more central barriers.
  • the one or more barriers form a lengthwise extension of one or more of the seams into the fluid distribution structure. More specifically, the one or more barriers that form the lengthwise extension of one or more of the seams into the fluid distribution structure are curved, bent, or linear, or a combination thereof. Yet more specifically, a plurality of barriers form a lengthwise extension of one or more of the seams into the fluid distribution structure and the plurality of barriers includes one or more central barriers parallel to the seams and one or more flanking barriers curved, bent, or angled towards the one or more central barriers.
  • the one or more barriers form a discontinuous and lengthwise extension of one or more of the seams into the fluid distribution structure. More specifically, a plurality of barriers form a discontinuous and lengthwise extension of one or more of the seams into the fluid distribution structure and the plurality of barriers includes one or more central barriers parallel to the seams and one or more flanking barriers curved, bent, or angled towards the one or more central barriers.
  • the one or more barriers include a void space.
  • the void space can have a variety of shapes, such as a diamond, circle, oval or triangle.
  • the one or more barriers include a void space in combination with the one or more barriers described in any of the above aspects of this embodiment of the invention.
  • the one or more barriers are arranged in a staggered pattern. Specifically, the one or more barriers are arranged to provide alternating sequences of separated channel flows and un-separated channel flows in the fluid distribution structure, whereby the one or more barriers distribute each un-separated channel flow into two or more channel flows.
  • Embodiments of the fluid distribution structure are not limited to the displayed patterns and can utilize various combinations and patterns not shown.
  • the internal pressure created by the culture medium, microorganisms and gases create a hoop stress in the capsule.
  • the hoop stress is calculated by the following equation:
  • Table 1 shows the load in the film per linear inch of film (lb/in) at three different operating pressures assuming a 46mm lay flat width (LFW) channel (29mm or 1.14in inflated diameter) or a 160mm LFW header (102mm or 4.02in inflated diameter). The values are calculated following a hoop stress analysis. No factor of safety is applied to the allowable load in the film or seam. These values can be compared to the measured mechanical properties of the film or seam to verify that the film or seam is capable of handling the operating conditions.
  • LFW lay flat width
  • 160mm LFW header 102mm or 4.02in inflated diameter
  • 'factor of safety means that the maximum load a film capsule can bear with less man 20% strain at a particular operating pressure is a factor greater than the maximum calculated load on the film capsule at the same operating pressure, as determined by a hoop stress analysis and conversion to load.
  • the factor is 3 times, 2 times, or 1.5 times. In other embodiments, the factor is at least 3 times, at least 2 times or at least 1.5 times.
  • the operating pressure is at least 2 psi, at least 4 psi, at least 6 psi or at least 10 psi.
  • the factor of safety is at least 3 at an operating pressure of 2 psi. In other embodiments, the factor of safety is at least 3 at an operating pressure of 4 psi.
  • the maximum load a capsule can bear with less than 20% strain can be measured using a creep test.
  • the one or more seams of the elongated body has a maximum load in a T-peel test that is greater than a maximum load of the flexible polymer film at less than 20% strain in a tensile test.
  • the one or more seams of the fluid distribution structure has a maximum load in a T-peel test mat is greater than a maximum load of the flexible polymer film at less than 20% strain in a tensile test.
  • the one or more seams of the fluid distribution structure and/or the elongated body and the polymer film forming the fluid distribution structure and or the elongated body are designed for operation at a pressure of at least 2 psi with a factor of safety of at least three.
  • the one or . more seams of the fluid distribution structure and/or the elongated body and the polymer film forming the fluid distribution structure and/or the elongated body are designed for operation at a pressure of at least 4 psi with a factor of safety of at least three.
  • One embodiment of the invention is a photobioreactor incl uding a capsule and an external pressure plate (e.g., an external clamshell, a C-tube) designed to reduce the load on the capsule film or seam.
  • ⁇ pressure plate can also be used to improve or manage fluid flow within the photobioreactor.
  • a pressure plate is made of a material of greater stiffness than the capsule film (e.g., aluminum, rigid polyvinyl chloride, acrylic, fiber-reinforced composites).
  • FIG. 8 is a schematic diagram and shows a photobioreactor capsule having channels 806 and fluid distribution structure 820, and external pressure plate 832.
  • FIG. 9 is a schematic diagram and illustrates top plate 936 of pressure plate 932 from several perspectives: plan view 931, front view 933 and side view 935.
  • Pressure plate 932 includes base plate 934, top plate 936, fins 938, and means for applying a substantially even amount of pressure through top and base plates 936 and 934 to fins 938.
  • Base plate 934, top plate 936, and the means for applying pressure cooperate to reduce the load on the capsule film.
  • fins 938 located on top plate 936 and bottom plate 934 align with one another and with the channel seal ends. Fins 938 apply pressure to the channel seal ends, thereby reinforcing the channel seams.
  • Base and top plates 934 and 936 can be reinforced with additional beams to support the internal pressure of the photobioreactor without excessive deflection of the plates.
  • a pressure plate can allow for higher operating pressures by reducing hoop stress in the capsule film and isolating the ends of the channel seals from stress in those areas.
  • a fluid distribution structure is sandwiched between the top and base plates such that the fins on the top plate and the fins on the bottom plate align with the seal ends that form the boundaries of the channels.
  • the plates are held closed with clamps or bolts, which apply pressure through the fins and squeeze the channel ends located between the base and top fins.
  • the plates limit the amount of deformation of the bioreactor. That is, the bioreactor will expand only to the extent allowed by the plates, thus limiting the unsupported periphery of the bioreactor to the space between the plates. This significantly reduces the hoop stress in the capsule film. By pinching the ends of the channel seals between the fins of the pressure plate, separation, tearing or peeling of the top and bottom sheets of the photobioreactor is prevented.
  • An additional benefit of a pressure plate is that the fins help to shape the ends of the channels, thereby preventing wrinkles in the capsule film that could reduce culture flow into individual channels or lead to maldistribution of the culture medium.
  • a photobioreactor includes a capsule and a pressure plate, such as a C-tube.
  • FIG. 12 is a schematic diagram and shows an exemplary C-tube assembly of the invention.
  • Disassembled C- tube assembly 1248 includes C-tube 1240, pin 1244 and adjustable plug 1242.
  • Pin 1244 and adjustable plug 1242 are designed to manage pressure and length of a fluid distribution structure in a capsule with a fluid distribution structure in the form of an integrated header.
  • the depiction of assembled C-tube assembly 1249 shows adjustable plug 1242 inserted into C-tube 1240 and held at a desired location by pin 1244.
  • Head-on view 1246 of an exemplary C-tube assembly of the invention also shows adjustable plug 1242 inserted into C-tube 1240 and held at a desired location by pin 1244.
  • FIGS. 7A and 7B a cross-sectional diagram of a thin-film capsule inflated 602A and deflated 602B is shown in accordance with the present invention, according to certain embodiments.
  • Thin-film capsules 602A and 602B include one or more channels (606A, 606B, 606C, and 606D).
  • top sheet 608 and bottom sheet 610 are sealed lengthwise along both outside edges 612 and seams 614.
  • One or more channels (606A, 606B, 606C, and 606D) are inflated and filled with the culture medium and a phototrophic microorganism, as shown in FIG. 7A.
  • the culture medium of the phototrophic microorganism can be provided in a layer of liquid or semi-liquid that flows through each channel (606A, 606B, 606C, and 606D).
  • this layer may typically be between about 5 mm and about 30 mm deep, between about 10 mm and about 15 mm deep, between about 10 mm and 30 mm deep or between about 20 mm and 30 mm deep.
  • a mixture of gases can be provided.
  • This mixture of gases can be used to feed the microorganisms and or be exhausted by the phototrophic microorganisms.
  • a combination of gas pressure; thickness or volume of the layer of culture medium of the phototrophic microorganisms; and strength of top sheet 608, bottom sheet 610, and outside edges 612 and seams 614 can be used to determine inflated width 614A of channels 606A-D.
  • the width of the channels (606A, 606B, 606C, and 606D) given the thickness or volume of the layer of culture medium of the phototrophic microorganisms and strength of the top sheet 608, the bottom sheet 610, and outside edges 612 and seams 14.
  • the maximum hoop stress ⁇ can be determined for a given top sheet 608 and bottom sheet 610 strength. From the maximum hoop stress, a major cross-sectional dimension 614A can be determined.
  • major cross-sectional dimension or “major dimension” refers to the greatest cross-sectional dimension a channel assumes when it is inflated.
  • FIG. 7B shows an embodiment in which channels 606A-D are formed by seams 614 located at 180 degrees from one another.
  • Lay flat width 614B may typically be between about 1 mm and about 2 m, between about 15 mm and about 1 m, between about 15 mm and about 300 mm, or between about 10 mm and 100 mm.
  • lay flat width 14B shrinks to inflated diameter 614A of channels 606A-D.
  • Table 2 shows exemplary lay flat widths and the corresponding inflated diameters, assuming 180-degree seams.
  • “Diameter” is the major cross-sectional dimension of a channel whose cross-sectional shape approaches that of a circle.
  • the photobioreactor also provides methods to achieve organism
  • productivity as measured by production of desired products, which includes cells themselves.
  • the desired level of products produced from the phototrophs in the photobioreactor can be of commercial utility.
  • the phototrophs in the photobioreactor use light, water and carbon dioxide to produce carbon-based products of interest (e.g., fuels, biofuels, biomass or chemicals) at about 5 to about 10g/m 2 /day, in certain embodiments about 15 to about 42g/m 2 /day and in more preferred embodiments, about 30 to 45gm 2 /day or greater.
  • carbon-based products of interest e.g., fuels, biofuels, biomass or chemicals
  • Superior areal productivities are achieved by: optimizing cell culture density through control of growth environment, optimizing CO 2 infusion rate and mass transfer, optiinizing mixing to achieve highest photosynthetic efficiency/organisms, achieving maximum extinction of insulating light via organism absorption, and achieving maximum extinction of CO 2 and initial product separation.
  • the southwestern U.S. has sufficient solar insolation to drive maximum areal productivities to achieve about >25,000 gal/acre/year ethanol or about >15,000 gal/acre/year diesel, although a majority of the U.S. has insolation rates amenable to cost effective production of commodity fuels or high value chemicals.
  • CO 2 is also readily available in the southeastern U.S. region, which is calculated to support large scale commercial deployment of the invention to produce 25 - 70 g/m 2 /day ethanol, or 70 Bn gal/year diesel.
  • a fourth embodiment of the invention is a method of producing a carbon-based product in a photobioreactor or capsule of the invention, comprising culturing a phototrophic microorganism that produces the carbon- based product in a photobioreactor or photobioreactor capsule, the culturing comprising flowing culture medium containing the phototrophic microorganism into the fluid distribution structure at an operating pressure of greater than about 2 psi, thereby distributing culture medium to a substantially even depth across the plurality of adjacent channels; flowing the distributed culture medium through the plurality of adjacent channels; and providing carbon dioxide to the culture medium, whereby the phototrophic microorganism receives light of a wavelength that is photosynthetically active in the phototrophic microorganism.
  • a fifth embodiment of the invention is a method of producing a
  • the photobioreactor comprising a capsule comprising an elongated body divided widthwise into a plurality of adjacent channels, the elongated body having a length of at least 50 m and a width of about 1 m to about 2 m, inclusive, and including a first top wall and a first bottom wall sealed lengthwise to form two or more seams that form the plurality of adjacent channels; and a fluid distribution structure including a second top wall coupled to the first top wall and a second bottom wall coupled to the first bottom wall, wherein the first and second top walls are formed from a first single piece of a flexible polymer composite film and the first and second bottom walls are formed from a second single piece of the flexible polymer composite film, the flexible polymer composite film is at least partially transparent to light of a wavelength that is photosynthetically active in a phototrophic microorganism, and each channel has a
  • phototrophic microorganism into and through the fluid distribution structure at an operating pressure of greater than about 2 psi, thereby distributing culture medium to the plurality of adjacent channels; flowing the distributed culture medium through the plurality of adjacent channels; providing carbon dioxide to the culture medium; providing light of a wavelength that is photosynthetically active in the phototrophic microorganism to the phototrophic microorganism as it flows through the plurality of adjacent channels, whereby the phototrophic microorganism produces the carbon-based product; and collecting the carbon- based product.
  • providing light includes locating a photobioreactor capsule in an area that receives light (e.g., sunlight) and positioning a light source such that at least a portion of the photobioreactor capsule receives light.
  • light e.g., sunlight
  • a sixth embodiment of the invention is a method of producing a
  • the phototrophic microorganism is a genetically engineered phototrophic microorganism.
  • the operating pressure is greater than about 4 psi.
  • the culture medium is distributed to a substantially even depth across the plurality of adjacent channels.
  • the substantially even depth across the plurality of adjacent channels is about 5 to about 30 mm. In yet a more specific aspect of the fourth, fifth or sixth embodiment, the substantially even depth across the plurality of adjacent channels is about 20 to about 30 mm.
  • the method comprises continuously flowing the culture medium containing the phototrophic microorganism into and through the fluid distribution structure.
  • continuous flowing means flowing culture medium into and through a photobioreactor capsule for long periods of time (e.g., days, weeks, or months) at an operating pressure (e.g., at least about 2 psi, at least about 3 psi, or at least about 4 psi).
  • "Continuously flowing" into the photobioreactor capsule (and, particularly, into the fluid distribution structure of a photobioreactor capsule) can be at a substantially constant flow rate or at a flow rate variable with time, and does not exclude stoppages or pauses in flow that may be necessary, for example, to perform maintenance or sampling on a photobioreactor.
  • the photobioreactors and the photobioreactor capsules of the invention can be operated under continuous flow conditions without significant structural problems, for example, failure of the capsule film or seams.
  • Another embodiment of the invention is a method of culturing a
  • the method comprising flowing culture medium containing the phototrophic microorganism into and through the fluid distribution structure at an operating pressure of greater than about 2 psi, thereby distributing culture medium across the plurality of adjacent channels; flowing the distributed culture medium through the plurality of adjacent channels; providing carbon dioxide to the culture medium; and providing light of a wavelength that is photosynthetically active in the phototrophic microorganism to the phototrophic microorganism as it flows through the plurality of adjacent channels, thereby culturing the phototrophic microorganism.
  • microorganisms and culture medium are distributed to a substantially even depth across the plurality of adjacent channels by seams in the fluid distribution structure positioned to provide alternating sequences of separated channel flows and un-separated channel flows. Yet more specifically, each un- separated channel flow is re-distributed into two or more channel flows by additional seams in the fluid distribution structure.
  • the substantially even depth across the plurality of adjacent channels averages between about 5 mm to about 30 mm. In a more specific aspect of this embodiment, the substantially even depth across the plurality of adjacent channels averages between about 20 mm to about 30 mm.
  • Suitable phototrophic microorganisms can produce a carbon-based product and/or the phototrophic microorganism itself can be processed as feed stock for the production of a carbon-based product.
  • Particularly suitable phototrophic microorganisms can be genetically engineered to produce a desired carbon-based product.
  • Exemplary suitable phototrophic microorganisms are described in U.S. Patent No. . 7,919,303, U.S. Patent No. 7,794,969, U.S. Patent Application No. 12/833,821, U.S. Patent Application No. 13/054,470, U.S. Patent Application No. 12/867,732, WO/2009/111513, WO/2009/036095, WO/2011/005548, WO/2011/006137 and WO/2011/011464.
  • Carbon-based products of interest include alcohols such as ethanol, propanol, isopropanol, butanol, fatty alcohols, fatty acid esters, ethyl esters, wax esters; hydrocarbons and alkanes such as pentadecane, heptadecane, propane, octane, diesel, Jet Propellent 8 (JP8); polymers such as terephthalate, 1,3 - propanediol, 1 ,4-butanediol, polyols, Polyhydroxyalkanoates (PHA), poly-beta- hydroxybutyrate (PHB), acrylate, adipic acid, ⁇ -caprolactone, isoprene, caprolactam, rubber; commodity chemicals such as lactate, docosahexaenoic acid (DHA), 3-hydroxypropionate, ⁇ -valerolactone, lysine, serine, aspartate, aspartic acid,
  • alcohols such as
  • carotenoids isoprenoids, itaconic acid
  • pharmaceuticals and pharmaceutical intermediates such as 7-aminodeacetoxycephalosporanic acid (7- ADCA)/cephalosporin, erythromycin, polyketides, statins, paclitaxel, docetaxel, terpenes, peptides, steroids, omega fatty acids and other such suitable products of interest.
  • Such products are useful in the context of biofuels, industrial and specialty chemicals, as intermediates used to make additional products, such as nutritional supplements, neutraceuticals, polymers, paraffin replacements, personal care products and pharmaceuticals.
  • More typical carbon-based products of interest are fuels (e.g., alcohols
  • carbon- based products of interest are ethanol, propanol, isopropanol, butanol, terpenes, alkanes such as pentadecane, heptadecane, octane, propane, fatty acids, fatty esters, fatty alcohols, olefins or diesel.
  • light of a wavelength that is photosynthetically active in the phototrophic microorganism refers to light that can be utilized by the microorganism to grow and/or produce carbon-based products of interest, for example, fuels, including biofuels.
  • transparent refers to an optical property that allows passage of light of a wavelength that is photosynthetically active in the phototrophic microorganism and or other desirable wavelengths of light.
  • a channel refers to a sheet or sheets of material that have the ability to flex or bend under a relative force or pressure applied to a surface during operation.
  • a channel can be formed by bonding two or more flexible walls collinearly and lengthwise, providing bonded seams.
  • a channel can be formed by a single flexible wall in the form of a tube.
  • thin-film refers to a flexible film, for example, a polymer or polymer composite film. Thickness of the film or sheet can be less than 500 micrometers, preferably from about 100 to about 250 micrometers.
  • Photosynthesis Such organisms include eukaryotic plants, algae, protists and prokaryotic cyanobacteria, green sulfur bacteria, green non-sulfur bacteria, purple sulfur bacteria, and purple non-sulfur bacteria.
  • Phototrophs include natural and engineered organisms that carry out photosynthesis and hyperlight capturing organisms.
  • the photobioreactors of the present invention are adapted to support a biologically active environment that allows chemical processes involving photosynthesis in organisms such as phototrophic organisms to be carried out, or biochemically active substances to be derived from such organisms.
  • the photobioreactors can support aerobic or anaerobic organisms.
  • organisms encompasses autotrophs, phototrophs, heterotrophs, engineered light capturing organisms and at the cellular level, e.g., unicellular and multicellular.
  • light generally refers to sunlight but can be solar or from artificial sources including incandescent lights, light-emitting diodes (LEDs), fiber optics, metal halide, neon, halogen and fluorescent lights.
  • LEDs light-emitting diodes
  • fiber optics metal halide, neon, halogen and fluorescent lights.
  • psi refers to psig (psi gauge).
  • a photobioreactor capsule was fabricated from two sheets of a multilayer film.
  • the film was composed of five separate layers with the following construction:
  • LLDPE linear low density polyethylene
  • tie refers to a less than 5 urn tie layer used to adhere the two adjacent layers together, typically using an anhydride chemistry
  • PA-6/6,6 is a blend of nylon-6 and nylon-6,6 commonly referred to as nylon triple six.
  • the LLDPE and PA-6/6,6 layers contained UV stabilizers for weathering protection and likely other additives for processing and handling characteristics.
  • the total thickness of this multi-layer film was 9 mil (229 ⁇ ). Neglecting the thicknesses of the tie layers, the thicknesses of the polyethylene and nylon layers were:
  • This multilayer film was made via an extrusion process on a blown film line, giving a collapsed tube.
  • the collapsed tube was slit to the desired film width.
  • Two sheets of the film were joined together either by a thermal, heat sealing process or an extruded sealing process where a PE resin was used to create the channels along the length of the capsule.
  • the transition geometries were fabricated in a secondary step using a thermal, heat sealing process.
  • Table 3 is a list of the properties of a capsule constructed as described above.
  • Photobioreactor capsules 0.4 m wide and either 8 m or 50 m long were constructed of the film described in Example 1 and contained 8 channels with a center to center lay flat width (LF ) of 50 mm and a seal width of 4 mm.
  • the transition region of these capsules had a 10 degree taper leading to a connector attached to the fluid and gas piping.
  • an external pressure plate or "clamshell” was used to constrain the transition area and transfer the loads into the higher stiffness plates.
  • the clamshell also utilized narrow fins that provided a compressive force on the channel seal ends.
  • FIGS. 8 and 9 depict an exemplary pressure plate f om several perspectives.
  • photobioreactor capsules using a wild type cyanobacteria as well as a genetically-modified cyanobacteria.
  • the capsules were operated for the times and pressures listed in Table 4.
  • FIGS. 4A-4G Alternative geometries that can be used with or without a pressure plate were evaluated through pressure testing in the lab.
  • the prototypes whose fluid distribution structures are depicted in FIGS. 4A-4G had 8 channels and a total lay flat width of 0.40 m to 0.45 m.
  • FIG. 5D is an illustration of a prototype having 22 channels and a total lay flat width of about 1 m.
  • FIG. 10 depicts a photobioreactor capsule with an integrated header.
  • FIG. 11 shows that the capsule with the integrated header having a 100mm inflated diameter had more even channel flow velocity than the capsule with the integrated header having a 50mm or 75 mm inflated diameter.
  • Table 5 shows the results of the qualitative flow tests on 17-channel capsules having integrated headers of varying inflated diameters and with or without a c-tube, such as that depicted in FIG. 12.
  • “HughTube” is a c-tube, such as that depicted in FIG. 12, in which the opening of the "c” is oriented at approximately parallel to the ground;
  • “HughTube Rotated” indicates the HughTube has been rotated up and away from the horizontal by about 70 to about 80 degrees.
  • Table 6 shows the results of the qualitative flow tests on 8-channel capsules having in-line, tapered fluid distribution structures.
  • “Diamond Transition” refers to the fluid distribution structure depicted in FIG. 4F;
  • “Split Transition” refers to the fluid distribution structure depicted in FIG. 4D;
  • “Split Manifold Transition” refers to the fluid distribution structure depicted in FIG. 4G.
  • the photobioreactor with an integrated header can optionally have a pressure plate designed to manage the pressure in the photobioreactor.
  • FIG. 12 is an example of a C-tube with adjustable plug that is designed to manage pressure and length of the header in a capsule with an integrated header.

Landscapes

  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Zoology (AREA)
  • Organic Chemistry (AREA)
  • Bioinformatics & Cheminformatics (AREA)
  • Chemical & Material Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Genetics & Genomics (AREA)
  • Biotechnology (AREA)
  • Sustainable Development (AREA)
  • Microbiology (AREA)
  • Biochemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • General Health & Medical Sciences (AREA)
  • Biomedical Technology (AREA)
  • Clinical Laboratory Science (AREA)
  • Molecular Biology (AREA)
  • Apparatus Associated With Microorganisms And Enzymes (AREA)

Abstract

La présente invention concerne un photobioréacteur pour un micro-organisme phototrophe, et un milieu de culture pour celui-ci, comprenant une capsule, la capsule comprenant un corps allongé comprenant un premier film polymère flexible qui est au moins partiellement transparent à la lumière d'une longueur d'onde qui est photosynthétiquement active dans un micro-organisme phototrophe et divisée dans le sens de la largeur en une pluralité de canaux adjacents, chaque canal ayant une dimension transversale majeure qui est non supérieure à environ un tiers de la longueur du corps allongé lorsque le corps allongé est gonflé ; et une structure de distribution de fluide couplée au corps allongé approprié pour une communication fluidique avec la pluralité de canaux adjacents qui distribuent un écoulement de milieu de culture parmi la pluralité de canaux, la structure de distribution de fluide étant composée d'un second film polymère flexible.
PCT/US2012/049150 2011-08-05 2012-08-01 Photobioréacteurs flexibles, systèmes et procédés WO2013022670A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US14/237,054 US20140186909A1 (en) 2011-08-05 2012-08-01 Flexible Photobioreactors, Systems and Methods

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US201161515552P 2011-08-05 2011-08-05
US61/515,552 2011-08-05
US201261598196P 2012-02-13 2012-02-13
US61/598,196 2012-02-13

Publications (1)

Publication Number Publication Date
WO2013022670A1 true WO2013022670A1 (fr) 2013-02-14

Family

ID=46796717

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2012/049150 WO2013022670A1 (fr) 2011-08-05 2012-08-01 Photobioréacteurs flexibles, systèmes et procédés

Country Status (1)

Country Link
WO (1) WO2013022670A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8586353B2 (en) 2006-11-02 2013-11-19 Algenol Biofuels Switzerland GmbH Closed photobioreactor system for continued daily In Situ production of ethanol from genetically enhanced photosynthetic organisms with means for separation and removal of ethanol
WO2014197766A1 (fr) * 2013-06-07 2014-12-11 Joule Unlimited Technologies, Inc. Bioréacteurs flexibles, systèmes et procédés
US10272639B2 (en) 2015-03-23 2019-04-30 Emd Millipore Corporation Abrasion resistant film for biocontainers

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2335199A (en) * 1998-03-11 1999-09-15 Applied Photosynthetics Limite Photobioreactor apparatus
GB2339763A (en) * 1998-07-24 2000-02-09 Applied Photosynthetics Limite Partitioned bag for use as photobioreactor
US20080206857A1 (en) * 2007-02-26 2008-08-28 Kenney David A Device and method for reducing bubble formation in cell culture
WO2009036095A1 (fr) 2007-09-10 2009-03-19 Joule Biotechnologies, Inc. Organismes collecteurs de lumière synthétisés par génie génétique
WO2009096773A1 (fr) * 2008-02-01 2009-08-06 Algaelink N.V. Procédé de fabrication d'un élément de réacteur d'un photo-bioréacteur, photo-bioréacteur et élément de réacteur destiné à celui-ci
WO2009111513A1 (fr) 2008-03-03 2009-09-11 Joule Biotechnologies, Inc. Microorganismes de synthèse fixant le co2 et produisant des produits carbonés d’intérêt
US7794969B1 (en) 2009-07-09 2010-09-14 Joule Unlimited, Inc. Methods and compositions for the recombinant biosynthesis of n-alkanes
US20100248333A1 (en) * 2009-03-30 2010-09-30 Bartilson Brad W Photobioreactor System and Method For the Growth of Algae for Biofuels and Related Products
WO2011005548A1 (fr) 2009-06-22 2011-01-13 Joule Unlimited, Inc. Biosynthèse d’alcènes-1 dans les micro-organismes modifiés
WO2011011464A2 (fr) 2009-07-20 2011-01-27 Joule Unlimited, Inc. Constructions et procédés pour la transformation efficace de micro-organismes pour la production de produits à base de carbone d'intérêt
US20110124087A1 (en) * 2008-01-18 2011-05-26 Aveston Grifford Ltd. Photobioreactor

Patent Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2335199A (en) * 1998-03-11 1999-09-15 Applied Photosynthetics Limite Photobioreactor apparatus
GB2339763A (en) * 1998-07-24 2000-02-09 Applied Photosynthetics Limite Partitioned bag for use as photobioreactor
US20080206857A1 (en) * 2007-02-26 2008-08-28 Kenney David A Device and method for reducing bubble formation in cell culture
WO2009036095A1 (fr) 2007-09-10 2009-03-19 Joule Biotechnologies, Inc. Organismes collecteurs de lumière synthétisés par génie génétique
US20110124087A1 (en) * 2008-01-18 2011-05-26 Aveston Grifford Ltd. Photobioreactor
WO2009096773A1 (fr) * 2008-02-01 2009-08-06 Algaelink N.V. Procédé de fabrication d'un élément de réacteur d'un photo-bioréacteur, photo-bioréacteur et élément de réacteur destiné à celui-ci
WO2009111513A1 (fr) 2008-03-03 2009-09-11 Joule Biotechnologies, Inc. Microorganismes de synthèse fixant le co2 et produisant des produits carbonés d’intérêt
US20100248333A1 (en) * 2009-03-30 2010-09-30 Bartilson Brad W Photobioreactor System and Method For the Growth of Algae for Biofuels and Related Products
WO2011005548A1 (fr) 2009-06-22 2011-01-13 Joule Unlimited, Inc. Biosynthèse d’alcènes-1 dans les micro-organismes modifiés
WO2011006137A2 (fr) 2009-07-09 2011-01-13 Joule Unlimited, Inc. Procédés et compositions pour la biosynthèse recombinante des n-alcanes
US7919303B2 (en) 2009-07-09 2011-04-05 Joule Unlimited, Inc. Methods and compositions for the recombinant biosynthesis of n-alkanes
US7794969B1 (en) 2009-07-09 2010-09-14 Joule Unlimited, Inc. Methods and compositions for the recombinant biosynthesis of n-alkanes
WO2011011464A2 (fr) 2009-07-20 2011-01-27 Joule Unlimited, Inc. Constructions et procédés pour la transformation efficace de micro-organismes pour la production de produits à base de carbone d'intérêt

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
PULZ, 0.: "Photobioreactors: Production systems for phototrophic microorganisms", APPL. MICROBIOL. BIOTECHNOL, vol. 57, 2001, pages 287 - 293, XP002582927, DOI: doi:10.1007/S002530100702

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8586353B2 (en) 2006-11-02 2013-11-19 Algenol Biofuels Switzerland GmbH Closed photobioreactor system for continued daily In Situ production of ethanol from genetically enhanced photosynthetic organisms with means for separation and removal of ethanol
WO2014197766A1 (fr) * 2013-06-07 2014-12-11 Joule Unlimited Technologies, Inc. Bioréacteurs flexibles, systèmes et procédés
US10272639B2 (en) 2015-03-23 2019-04-30 Emd Millipore Corporation Abrasion resistant film for biocontainers
US10675836B2 (en) 2015-03-23 2020-06-09 Emd Millipore Corporation Abrasion resistant film for biocontainers
US11110684B2 (en) 2015-03-23 2021-09-07 Emd Millipore Corporation Abrasion resistant film for biocontainers

Similar Documents

Publication Publication Date Title
US20140186909A1 (en) Flexible Photobioreactors, Systems and Methods
US9376656B2 (en) Photobioreactor system and method for the growth of algae for biofuels and related products
AU2014202766B2 (en) Photobioreactor systems positioned on bodies of water
US9637714B2 (en) Diffuse light extended surface area water-supported photobioreactor
US8722396B2 (en) Bioreactor assembly for culture of photoautotrophic algae
US8658420B2 (en) Photobioreactor for algae growth
US20160168521A1 (en) Bioreactors supported within a rack framework and methods of cultivating microorganisms therein
US20140134672A1 (en) Bioreactors circulation apparatus, system and method
WO2013022670A1 (fr) Photobioréacteurs flexibles, systèmes et procédés
WO2015087169A2 (fr) Bioréacteurs supportés dans un châssis à claies et procédés de culture de micro-organismes les utilisant
US20140329297A1 (en) Polymeric Thin-Film Tube Connectors, Bioreactors, Systems and Methods
US20140099685A1 (en) Bioreactors apparatus, system and method
US9896652B2 (en) Photobioreactor, system and method of use
WO2014197766A1 (fr) Bioréacteurs flexibles, systèmes et procédés
KR101608214B1 (ko) 온도조절이 가능한 광생물 반응장치
AU2014201960A1 (en) Improved diffuse light extended surface area water-supported photobioreactor
US9663749B2 (en) Reaction casing for a photosynthetic reactor and associated photosynthetic reactor
CN105219616B (zh) 一种软体板式光生物反应器
US20180298314A1 (en) Photobioreactor, System and Method of Use
WO2023092114A2 (fr) Système de culture d'algues aquatiques ouvert pourvu de sections de revêtement semi-perméables pour l'absorption environnementale améliorée de dioxyde de carbone
ITMO20130165A1 (it) Fotobioreattore per la coltivazione di vegetali in particolare microalghe

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 12754116

Country of ref document: EP

Kind code of ref document: A1

WWE Wipo information: entry into national phase

Ref document number: 14237054

Country of ref document: US

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 12754116

Country of ref document: EP

Kind code of ref document: A1