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Mario R. Tredici
Dipartimento di Scienze delle Produzioni
Agroalimentari e dell’Ambiente
Università degli Studi di Firenze
6-8 April 2016Real Marina Hotel Olhão, Portugal
Techno-economic analysis of microalgal
biomass production in a 1-ha Green Wall
Panel (GWP®) plant
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The Green Wall Panel (GWP®)
A suitable tool for production of commodities?
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GWP-I 7 April 2016 at 17:21
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Enel S.pA.
Brindisi, Italy
GWP-I
GWP-I
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Eni R&M 1- ha plant (Gela- Sicily)
GWP-I
GWP-I
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AlgaeFuel objectives: 1. Selection and molecular characterization of autoctonus
algal strains 2. Development of the basic engineering for design and
operation of a pilot plant for algae biomass production 3. Produce algal biomass at pilot level (1 ha) 4. Optimization of culture parameters in PBR and ponds 5. Maximize algal lipid and oil production (for biodesel) 6. Use of co-products as feed (evaluation of nutritional and
toxicological features of algae meal) 7. Create an economically viable and sustainable enterprise
for producing, at 300 ha level, oil for biodiesel and biomass for feed, using flue gas as CO2 source
AlgaeFuels (Atacama - Chile)
GWP-II
GWP-II
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The GWP III in Saudi Arabia
GWP-III
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The GREEN WALL PANEL Developed at Florence University and commercialised by Fotosintetica & Microbiologica Srl
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PHOTOFUEL - BIOCATALYTIC SOLAR FUELS FOR SUSTAINABLE MOBILITY IN EUROPE
Societal Challenges - Secure, clean and efficient energy
Call: H2020-LCE-2014-1; Topic: LCE-11-2014
List of participants 1 Volkswagen AG, Germany (Coordinator) 2 Uppsala Universitet, Sweden 3 Universität Bielefeld, Germany 4 Imperial College London, United Kingdom 5 Università degli Studi di Firenze, Italy 6 A4F Algafuel SA, Portugal 7 IFP Energies nouvelles, France 8 Neste Oil Corporation, Finland 9 Karlsruhe Institute of Technology, Germany 10 Centro Ricerche Fiat SCPA, Italy 11 VOLVO Technology, Sweden 12 SYNCOM F&E Beratung GmbH, Germany
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NOMORFILM - NOVEL MARINE BIOMOLECULES AGAINST BIOFILM. APPLICATION TO MEDICAL DEVICES.
CALL: H2020-BG-2014-2; TOPIC: BG-03-2014
Societal Challenges - Food security, sustainable agriculture and forestry, marine, maritime and inland water research, and the bioeconomy
Project ID: 634588
List of participants 1 Barcelona Centre for International Health Research, Spain
(Coordinator) 2 University of Coimbra, Portugal 3 University of Oviedo, Spain 4 Karolinska Institute, Sweden 5 University of Florence, Italy 6 University of Almería, Spain 7 Copenhagen University, Denmark 8 Trinity College of Dublin, Ireland 9 Fotosintetica & Microbiologica Srl, Italy 10 NanoMedPharma Ltd, United Kingdom 11 KTEDOGEN Srl, Italy 12 MBA Incorporado SL, Spain 13 PyroGenesis SA, Greece
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Cementa AB Degerhamn
Linnaeus University - Faculty of Health and Life Sciences Kalmar (Sweden)
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The GREEN WALL PANEL: commercial applications
MICROALGHE
CAMPOROSSO (Imperia-Italy)
GWP-I
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Algae biomass in the GWP – At which cost?
NER : the net energy ratio
Σ Energy produced (lipid or biomass)
Σ Energy requirements
An energy analysis NER
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The energy output
It is the total energy stored in the produced biomass of Tetraselmis suecica assuming an average caloric content of 22.2 MJ/ Kg dry biomass For Tuscany (13.4 MJ m-2 d-1) we assumed an average productivity of 15 g m-2 d-1 for 240 days (2.5% PE)
BIOMASS OUTPUT 36 t ha-1 year-1 ENERGY OUTPUT 799 GJ ha-1 year-1
NER of algae biomass production in a 1-ha GWP plant
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The energy inputs
The energy inputs: 1. Embodied energy 2. Fertilizers and chemicals 3. Operations
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Productivity gr m-2 day-1 15
Kg ha-1 day-1 150
Ton ha-1 year-1 36
Biomass energy content
MJ kg-1 22,2
Energy output
Eout in 240 days GJ ha-1 799
NER (EROI) of Tetraselmis biomass production in a 1-ha GWP-II plant producing 36 ton ha-1 yr-1 (240 days)
Eoperations* Eembodied** Efertilizer E tot NER GJ ha-1 GJ ha-1 GJ ha-1 GJ ha-1 -
Energy inputs
(240 days)
800 410 152 1362 0.6
**Partially from recycled material *Electric energy converted to primary energy
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Productivity gr m-2 day-1 20
Kg ha-1 day-1 200
ton ha-1 year-1 66
Biomass energy content
MJ kg-1 22,2
Energy output
Eout in 330 days GJ ha-1 yr-1 1465
NER (EROI) of Tetraselmis biomass production in a 1-ha GWP-II plant producing 66 ton ha-1 day-1 (330 operation days)
Eoperations Eembodied Efertilizer E tot in NER GJ ha-1 GJ ha-1 GJ ha-1 GJ ha-1 -
Energy inputs
(330 days)
1093 410 278 1781 0.82
NER > of 37%
Let’s move to a better location to improve productivity
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Photovoltaic integration
Gas recycling
Inclined panels to increase light interception and decrease material use per hectare
Thinner reactors
New materials to decrease embodied energy
The GWP III Decreasing the inputs
NER increased to 1.7
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When comparing energy crops we should not consider exclusively the NER…
With a NER of 3.7 can provide: an energy gain of 30 GJ ha-1 yr-1
a protein yield of ~ 1 t ha-1 yr-1
Algae at low NER, can provide 20 times the energy gain and 20 times more protein per unit occupied land than soybean
SOYBEAN ALGAE
With a NER of 1.7 can provide: an energy gain of 600 GJ ha-1 yr-1
a protein yield of > 20 t ha-1 yr-1
LCA and economic analyses of algae biofuels should duly consider the value of co-products and the efficiency of land use
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An economic analysis
Algae biomass in the GWP-II – At which cost?
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Main equipment and plant components
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Scheme of the 1-ha GWP®-II plant and process flow sheet. The plant consists of eight 1,250-m2 GWP®-II modules (GWP_1 to GWP_8) served by four main pipelines: a) the CO2-enriched gas supply pipeline that delivers flue-gas to the panels; b) the seawater pipeline that, fed by the submersible pumps, brings the seawater (after filtration) to the heat exchangers or delivers it to the storage tank where the growth medium is prepared; c) the growth medium pipeline used to transfer the fresh medium from the storage tank to the reactors and d) the culture harvesting pipeline that is used to transfer the culture from the modules to the centrifuges.
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Solid source of data
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Capital costs of a 1-ha GWP-II plant
Direct capital costs DEPRECIATION
(€/year)
GWP-II 505,320 35,225
Piping, fittings, valves, tanks 140,945 9,534
Machinery & Equipment 376,504 22,321
Electrical equipment & control 272,728 13,293
Laboratory and inoculum section 50,000 2,000
TOTAL direct costs
1,345,497
82,373
Installation (10% of direct costs) 134,550 5,382
Engineering (5% of direct costs) 67,275 2,691
Interest rate (2.5% of direct costs) 33,637
1,345
Total (€)
1,580,959
91,791
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Biomass production cost in a 1-ha GWP-II plant located in Tuscany (Italy)
Annual depreciation of CAPEX € 91,791
Annual operating costs
€
291,068
Labour € 179,400
Fertilizers € 7,620
Electricity € 37,526
Consumables € 6,980
Maintenance (1.5% DIRECT CAPEX) € 20,182
Overheads + administration € 39,360
TOTAL COSTS
€
382,860
Biomass production cost € kg-1 10.6
When located in Tuscany (Italy) the plant operates for 240 days at an average productivity of 15 g m-2 d-1
Annual productivity: 36 ton
Annual productivity: 36,000 kg
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Cost (€ kg-1) of T. suecica biomass produced in a GWP® -II plant in Tuscany and Tunisia at 1-ha and 100-ha scale
Tuscany Tunisia
1-ha scale TOTAL COST A- depreciation B- labour C- electricity
10.6 2.5 5.0 1.0
5.0 1.7 1.7 0.5
100-ha scale TOTAL COST A- depreciation B- labour C- electricity
4.0*
1.8 0.41 0.86
2.4**
1.2 0.14 0.41
* 3.3 no cooling
**1.8 no cooling
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Cost of microalgae biomass: 2€/kg
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The GWP® -I
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The GWP® -II
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250 m2 GWP-II modules used for inocula production at Camporosso (project EU FP7 BIOFAT - 2011-2016)
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GWP® – III
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The GWP® III.A 1. Automatic change of inclination 2. Gas recycling 3. Continuous dilution 4. Variable distance between panels 5. Multiple independent units
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The GWP® III.A
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The GWP® III.A
degasser
movable legs
Pneumatic cylinder
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1980 - The Vertical Alveolar
Panel
1990 - The Near Horizontal Tubular
Reactor
2016 – The GWP®-III.A
2004 – The GWP®
36 years
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The advancement of applied sciences is very slow…
There is a highly visible difference between the pace of basic science and the application of new knowledge to human problems ( Lewis Thomas- The Lives of a Cell)
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Decoupling We need to decouple food
production from impact on the environment…
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The negative externalities of agriculture
We can not continue with
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10 million hectares of arable land are lost every year
…soil loss due to erosion.
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thehui.wordpress.com/.../
…pesticides pollution that
affects soil, water and air
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oneocean.cbc.ca
www.ecofriend.com
nofishleft.wordpress.com
Ocean dead zones are increasing in number and size
Half of nutrients applied on
farm are lost in runoff,
leaching or erosion.
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Desertification
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Texas 1938
Do not forget the Dust Bowl!
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http://www.surfbirds.com/mb/media/living-planet-0207.jpg
http://www.sustainablescale.org/images/uploaded/causes%20of%20biodiversity%20loss%201.JPG
http://www.mondonotizie.net/wp-content/uploads/2012/04/deforestazione-italia.jpg
Deforestation and Biodiversity loss
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Food production is responsible for about 1/3 of GHG emissions (above all CH4 e N2O)
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Algae can provide nutrient-dense, protein-rich products:
1. In deserts or marginal areas
2. Without using freshwater and good soils
3. Without pesticides
4. Using nutrients with 100% efficiency
5. At much higher productivities than traditional crops
With suitable strains and technologies
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We are at the beginning of algae domestication…
There is a BUT: €/kg!
There is a HOPE:
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From “The Ring” (ffffound.com)
Thank you very much for your
attention!
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The EROI of the PV integrated GWP III = 1.73
An EROI/NER of 1.7 may seem not sufficient…
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Tubular and panel PBR developed by UNIFI and F&M In 60 years of applied phycology
Applied phycology starts in Florence in 1956 thanks to an intuition of Prof
. G Florenzano
1990s
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FIGURE CAPTIONS Figure 3 – 250-m2 GWP®-II modules at Microalghe Camporosso (Imperia, Italy). Modules used at Microalghe Camporosso within the activities of the EU FP7 project BIOFAT. a) general view of the plant; b) a particular of a module with the skid containing the electric cabinet, the control system, the blower, the pump, the plate heat exchanger and valves. Figure 4 – The GWP®-III.A photobioreactor. An automatically inclinable GWP® used for research and inoculum production at F&M facilities. The system is also in use at AlgaePARC (The Netherlands), University of Bergen (Norway), University of Las Palmas de Gran Canaria (Spain), KAUST (Saudi Arabia).
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CROP Biomass
yield (ton ha-1 yr-1)
Energy output
(GJ ha-1 yr-1)
Energy input
(GJ ha-1 yr-1)
NER or EROI
Energy gain
(GJ ha-1 yr-1)
Protein yield
(ton ha-1 yr-1)
Soya * 2.6
39.2
10.6 3.7
28.5
0.91
T. suecica (Tuscany)
36 799 1362 0.6 -563 16.2
T. suecica (Africa)**
56
1243
848
1.5
395 24.1
*Pimentel, USA (2009) ** in a PV integrated GWP
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Techno-economic analysis of microalgal
biomass production in a 1-ha Green Wall
Panel (GWP®) plant
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Scheme of one 1,250-m2 GWP®-II module. The module consists of twenty-four 48-m-long panels hydraulically connected at both ends by PVC manifolds that ensure homogeneous distribution of the culture by means of pump circulation. Each panel can be isolated by closing a valve, e.g. to be cleaned or for maintenance. The module displays a total panel surface area of 800 m2 and occupies a land surface area of 1,250 m2 (including piping and manifolds). Pipelines for culture circulation, seawater transfer, medium preparation, culture movement and gas supply, pumps, blowers, filters and the heat exchangers are shown.
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