intensification and scale up ofintensification and scale ... · intensification and scale up...
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Intensification and scale up ofIntensification and scale up of continuous algae synthesis reactorsg y
René Wijffelswww.algae.wur.nl
Food or Fuel? High productivity
Oil content: 20 60% Oil content: 20-60% 20,000-80,000 liter/ha/year oil Palm oil: 6 000 liter/ha/year Palm oil: 6,000 liter/ha/year
No ‘competing claims’G t Grow on seawater
Use of residual nutrients (CO2, N, P)
Co-products have value (e.g. lipids, proteins)
Developments driven by fuel industry
Chemical composition of microalgaep gSpecies Protein (%) Carbohydrates (%) Lipids (%) Nucleic Acid (%)
Scenedesmus obliquus
50 – 60 10 – 17 12 - 14 3 – 6
Scenedesmus dimorphus
8 – 18 21 – 52 16 – 40 -dimorphus
Chlorella Vulgaris 51 – 58 12 – 17 14 – 22 -
Spirogyra sp. 6 – 20 33 – 64 11 – 21 -
Dunaliella salina 57 32 6 -
Euglena gracilis 39 – 61 14 – 18 14 – 20 -
Prymnesium parvum 28 – 45 25 – 33 22 - 38 1 – 2
Porphyridium 28 – 39 40 – 57 9 – 14 -p ycruentum
Spirulina maxima 60 – 71 13 – 16 6 - 7 3 – 4.5
Carioca, J.O.B., J. Hiluy Filho, M. Leal, F. Macambira. 2009. The hard choice for alternative biofuels to diesel in Brazil. Biotechnol. Adv. 27: 1043-1050
Order of value
Feed for juvenile fish ω-3 fatty acids ω-3 fatty acids Carotenoids (lutein)
P t i Proteins C2C Biomaterials Biofuels Biofuels
Microalgae marketsgApplications Value/Kg
BiomassMarketvolume
Nutraceuticals (human consumption) €100 €60 million
Nutraceuticals (animal- and fish feed) € 5-20 € 3-4 billion
Bulk chemicals €1-5 >€ 50 billionBulk chemicals €1-5 >€ 50 billion
Biofuels < €0.40 > €1 trillion
Present market volume: € 1 billion Present market segment: biomass value > € 50/ kg Present market segment: biomass value > € 50/ kg Objective: market segment < € 0.40/ kg biomass
Is biorefinery needed?y
ChemicalsBiofuels
Depends on the market volume you want S
N removal140 €
Oxygen 256 €
Chemicals 200 €
Biofuels150 €
Food proteins 500 €
volume you want Production costs:
Sugars100 €Feed proteins
300 €
0.40 €/kg Value algae biomass:
Applications Value/Kg
Biomass
Marketvolume
g1.65 €/kg
sNutraceuticals (human
consumption)€100 €60 million
Nutraceuticals (animal- and fishfeed)
€ 5-20 € 3-4 billionfeed)
Bulk chemicals €1-5 >€ 50 billion
Biofuels < €0.40 > €1 trillion
Wijffels et al. (2010). Microalgae for the production of bulk chemicals and biofuels. Biofuels, Bioproducts, & Biorefining, 4: 287-295.
To replace all transport fuels in Europe*p p p
400 million m3 lipids needed 9.25 million ha surface area Equivalent to surface area of
PortugalPortugal 400 million tons of proteins
producedproduced 40 times the amount of soy
t i i t d i Eprotein imported in Europe
*Wijffels & Barbosa (2010) An outlook on microalgalbiofuels. Science. 379: 796-799.
To replace all transport fuels in Europe*p p p
400 million m3 lipids needed 9.25 million ha surface area Equivalent to surface area of
PortugalPortugal 400 million tons of proteins
producedproduced 40 times the amount of soy
t i i t d i Eprotein imported in Europe
*Wijffels & Barbosa (2010) An outlook on microalgalbiofuels. Science. 379: 796-799.
Commercial companies? p
LGem LGem Nannochloropsis
M k t l 375 €/k Market value: 375 €/kg Niche market (turn over < 1
M€/year Producers of commodities?
Technology immature Only end usersOnly end users No large investments
What breakthroughs do we need?g
Research in the context of a complete processId tifi ti f b ttl k Identification of bottlenecks
In depth research on these bottlenecks Integration for complete process Integration for complete process
energy (light & mechanical loca
tion
(ligh
t, te
mpe
ratu
re)
reac
tor t
ype
alga
e sp
ecie
s (g
row
th
char
acte
ristic
s)
Algae cultivation
energy (light & mechanical
nutrients (CO2, N, P)
H2O
others
solution containing biomass
other products (e.g. O2)
Pre and post processing
Environment
others
Slegers P.M., Wijffels R.H., van Straten G., van Boxtel A.J.B. (2011)Design scenarios for flat panel photobioreactors. Applied Energy 88: 3342-3353
Biomass production costp10.62 € / kg biomass1 ha
Labor 28% Power 22%
100 haP 42%
4.02 € / kg biomass
Power 42%
Centrifuge w estfalia separator AG Centrifuge Feed Pump Medium Filter Unit
Medium Feed pump Medium preparation tank Harvest broth storage tank
Seaw ater pump station Automatic Weighing Station w ith Silos Culture circulation pump
Installations costs Instrumentation and control Piping
89% decrease
Buildings Polyethylene tubes Photobioreactor Culture medium
Carbon dioxide Media Filters Air f ilters
Pow er Labor Payroll charges
Maintenance General plant overheads 0.4 € / kg biomass15 €/GJ
potential15 €/GJ
Norsker et al. (2011) Microalgal production- a close look at economics, Biotechnology Advances 29: 24-27
Sensitivity analysis
Curacao PE 5% CO2 Incentive medium and CO2 free
Mixing w ith 10* less energy
Mixing 10*, PE 5%, CO2 incentive, mdium and CO2 free
Curacao PE 5%, CO2 Incentive, medium and CO2 free
CO2 incentive (15 € / ton CO2)
No centrifugation
PE 5%; CO2 and medium for free, CO2 incentive
Dilution rate 10% v/v per day
Photosynthetic Eff iciency 5%
( )
Culture medium for free
CO2 for free
Both CO2 and medium for free
-100 -90 -80 -70 -60 -50 -40 -30 -20 -10 0
% Decrease in production cost
Maximization of productivity/yieldp y y9.0 %
reflection on PBR x 0 96reflection on PBR x 0.96
night biomass loss x 0 908.6 %
night biomass loss x 0.90
maintenance x 0 957.8 %
maintenance x 0.95
What’s left ?... 7.4%Light saturation?Light saturation?Nutrient limitations? CO2
I hibiti ? O li htProcess designca 50% reduction in
production cost
Practice?... 3 - 4%Inhibition? O2, light
The principle of light dilution – go vertical!p p g g
Light dilution in the labg
Dilution of light By vertical flat panels By vertical flat panels Imitation of day/night cycles Model system: Chlorella sorokiniana 1 4 cm panel reactor 1.4 cm panel reactor
Cuaresma, Janssen, Vilchez & Wijffels (2009) Productivity of Chlorella sorokionana in a short light path photobbioreactor under high irradiance..Biotechnol. Bioeng. 104: 352-359.
Light dilution in the labg
2000
2500
s-1
Vertical east-westhorizontal PE = 4.2 %
1500
crom
ol m
-2 s
500
1000
PFD
/ m
i
PE = 6.5 %
00 200 400 600 800 1000 1200 1400
Time / min
Light dilution in practiceg p
Vertical panels Submerged (Solix
Biofuels) Inflatable bags (Proviron)
Wageningen UR algae researchg g g Interaction between basic research and
pilotsp Multidisciplinary approach Research topics S t Research topics
Efficient use of sunlightR d ti f i t
Application
development
Design
Systems
Design
Systems
Biology
Metabolic
Modelling Reduction of energy input Maximization productivity Product
i
development
Fermentation
t h lChains
Design
Strain
D l t
Modelling
metabolites Biorefinery
processing technologyDevelopment
Bioprocess
EngineeringBiorefinery Scale up Design scenarios/LCA’s Analytics
Engineering
Scale-up
y
When are algae biofuels commercial?g
Optimists: within 2 years Pessimists: never Pessimists: never We say: 10-15 years from now
F f d li i For food applications: sooner Scale Value
Why will it take 10-15 years?y y
Martek: DHA production C h di i h iiCrypthecodinium cohnii
Development fermentation process
Reduce risks to shorten time to market
10 years to develop 10 years to develop commercial process
Commercial algal biofuels? Commercial algal biofuels? 10-15 years
Bill Barcley, Algae oil production. Keynote lecture at the Algal BiomassOrganization 2009 summit, San Diego; October 7–9 (2009)
Research facility in Matalascañas, Spain
Translate research towards applicationsppStage 1 R&D Stage 2 test & pilot Stage 3 Scale-up
DemosFundamental
Research2.4 m2 24 m2
Demos>10 000 m2
Research
Encountered problems are to be rethought and solved at previous stages
AlgaePARC Industrial partnersWageningen UR
AlgaePARCgAlgae Production and Research Centre
AlgaePARC in the newsg
Volkskrant NRC
FranfurterFranfurter AllgemeineFinancieel
Dagblad
AlgaePARC objectivesg j International centre of applied
research Intermediate between basic
research and applicationsresearch and applications Development of competitive
technology (economicstechnology (economics, sustainability)A i i f ti f f ll Acquire information for full scale plants
Algal biomass for food, feed, chemicals and fuels
Research planp
Comparison and optimization of photobioreactors (24 m2)
Screening species on residual nutrients
Development of production strategies Field tests of production strategies
(2.4 m2)L l l (24 Long term tests at large scale (24 m2)D i t l t t i Dynamic process control strategies
Life Cycle Assessment
AlgaePARCg Facility financed by
Ministry EL&I Province Gelderland Wageningen UR
Research program financed by
AlgaePARC successful after 5 years ifg y
Improved reactor concept p pand/or process strategy PE > 5% Production costs < € 1 Positive energy balancegy Minimal use of fresh water
Sufficient basic information for Sufficient basic information for design of large-scale production facilityproduction facility
Dream Stand alone algae
production*production* Algae production on
seawater Prevention of evaporation
Phosphate/nitrogen Make use of residual
feedstocks Do not use P/N at all: milking
of microalgae** Growth on atmospheric CO2
From Feyecon
*Wijffels R.H., Janssen M., Barbosa M.J. (2011) Stand alone biofuel production from algae– Crystal ball 2011. Microbial Biotechnol. 4: 132-134
**Hejazi M.A., Wijffels R.H. (2004) Milking of microalgae. Trends Biotechnol. 24: 189-194
Our longer term missiong
T h l l f Technology platforms:Large industrial consortia Production: AlgaePARC Biorefinery: our next stepy p
Production platform: Products of specific interest to individual Products of specific interest to individual
companies Demonstration projectsp j
Conclusions Development of scalable
technologytechnology Sustainable production of
b lk dbulk products Biofuels (biodiesel) Food (protein, oil) Feed (protein, oil) Chemistry (amino acids, oil) Materials (silica,
polysaccharides) Educate
Research facility in Matalascañas, Spain
