microalgae: new drivers for ad & manure valorization · microalgae: new drivers for ad &...

MICROALGAE: NEW DRIVERS FORAD & MANURE VALORIZATION

Ed Weinberg, PE, ESSRE ConsultingSean FitzPatrick, AvAer PartnersBob Mroz, CEO, HY-TEK Bio

May 12, 2015

NC is the 2nd largest swine and turkey producer in the US NC has the largest bioenergy reserves on the East CoastNC is the Saudi Arabia of Nutrients

OVER 1.34 Million Tons of Poultry Litter80.4 Million Lbs. of N per Annum at 60 lbs per Ton 29.4 Million Lbs. of TP per Annum at 22 lbs per Ton

OVER 30 Million GPD of Swine Effluent309 Thousand Lbs. of N per DAY based on 10.3 lbs per 1,000 Gal 1.3 Million Lbs. of TP per DAY based on 25 Lbs per 1,000 Gal.

> 150 Thousand MTPA of Sewage Sludge from Waste Water Treatment Plants

> 1,800,000 MWh/yr (potential) electric generation from NC swine manure biogas

©2015 ESSRE C lti I

Introduction & Background Extent and Nature of Manure in North Carolina Environmental Liabilities Provide an Opportunity via Advances in Algae Technology Optimizing the Nutrient-Energy-Water Nexus

Advances in Microalgae Commercialization CO2 from Manure Digesters used for Mass Growth of Microalgae Enhanced Nutrient Reduction via Algae Growth Harvested Microalgae: Very Good Substrate for Co-Digestion Microalgae as an Economic Jolt to Digester Projects and Profitability

Nutrient Recovery Mass Algae Growth Requires Concentrated Nutrient Demands Nutrients from Poultry Litter: Proprietary Extraction Novel Nanomaterials for Nutrient Extraction and Concentration

Anaerobic Digestion is regarded as the best processing system for swine and poultry waste but there are problems due to high CAPEX and low biogas production.

Anaerobic Digestion of sewage sludge is a proven method of Bioenergy and solids reduction.

Algal Biomass as a Co-Digestate increases Biogas production from 20% to 70%.

Algae as a Co-Digestate inwaste makes the remaining Digestate a high quality timed release fertilizer with over 60% of N available 60 days after application.

©2015 ESSRE Consulting, Inc.

Make high value products from farming Algae extracts (N-E-W) Optimize Biogas Production with Algae biomass Co-Digestate (E) Mitigate CO2 and NOx emissions by using them for mass Algae

Production (E) Improved quality of digestate that can be used as Biofertilizer (W) Unique proprietary and nanomaterials for extracting, “exporting”,

and reusing excess manure nutrients to fully remediate the liquid fraction of digestate (N + W)

Leverage nutrient surplus for hydroponic cultivation of switchgrasson site for digester or for bedding (N-E-W)


Privately held – Headquartered in Dayton, Maryland between Baltimore and Washington, DC; Technology Center located at the Baltimore, MD BackRiver WRRF.

Incorporating Anaerobic Digestion into Algae Production since July 2012.

CO2 and NOx mitigation rates of 85% and 100% respectively, via 1/15th pilot scale bioreactors; fully scaled system will provide 100% mitigation capability.

Confidential and Proprietary - HY-TEK Bio © 2009 - 2015

HY-TEK Bio, LLC. Is a technology provider of patent-pending Algae-based GHG Mitigation and Nutrient Recovery Systems

Algae and algae oil is used in the following products (partial list) Eye surgery and eye cleansing solutions.

Skin conditioners.

Omega-3 Fatty Acid Nutraceutical products.

Cosmetic and paint thickeners.

Bioplastics.

Animal and human food supplements.

Biofuels

The HY-TEK Bio algae strain HTB-1 can bring as much as $40/lb from an algae brokerage house.

90-95% Oxygen from photosynthesis is a marketable commodity.

Direct replacement for Palm Oil.


FIVE KEY COMPONENTS TO GHG MITIGATION:

1. ALGAE – A unique strain of algae indigenous to the Chesapeake Bay, sHTB1, that rapidly consumes NOx, CO2 GHGs and other emissions; robust, fast growing thrives at up to 100% CO2 levels; and, is high in lipid oil and other more highly valued, marketable products.

2. CONTAINMENT – Employs a patent-pending tank construction using a laminated Mylar/Kevlar bond that reduces the cost of closed bioreactors by 90%.

3. LIGHTING – Employs a patent-pending high intensity LED Grow Light System that uses only photosynthesis light combined with a “flash effect” that enhances algal growth to produce more mitigation per volume of algae.

4. GAS INJECTION – A patent-pending flue gas injection system that assures rapid transfer of gas chemistry to the algal culture for enhanced algal growth and improved light scattering.

5. NUTRIENT – Patented and patent-pending processes that extract nutrient from wastewaters, livestock waste and are reused to produce maximum growth and density of the algal strain.


Breakthrough, Patent-Pending & Natural Clean Energy Solution

CO2 Results 85% Removal Efficiency (RE) 11.8 % vol CO2 IN; 1.8% vol CO2 OUT

NOx Results 100% Reduction 280 ppmv IN – Non-Detect (ND) OUT

Data Derived from 1/15th Scale Bioreactor Approx. 6 cfm, 1.5 ft diam., 6 ft. algae culture

Early Version Reactor Design -All of the Key Components Not Available


Growth & Harvesting – sHTB1 Specific Growth = <1 day Culture Density = 5 g/L 78 lb/day/reactor Oil Lipid Content = 48% Aerial Utilization = 1.6 kg/m2/day (20 bioreactors)

Production & Financial Projections (20 bioreactors) 800 lb Algae per day (approx. half the pilot rate) Daily Algae Revenue = 800 * $10/lb = $8000 Annual Revenue = $2.6MM Initial Capital Investment = approx. $4MM Simple Payback Period = < 2 years and Annual ROI = 45%; IRR = >20% (derated); > 45% at pilot production metrics

Algae Revenue Drives the Profit Engine for Owner/Operators & Technology Providers Algae Facility Installation and Operations Are Paid for by Algae RevenueMultitude of Product Markets – Highest Valued is Lutein at $1000/lbCO2 Utilization, NOx Mitigation, O2 production, for Profit


High Purity O2 Gas Production Commodity Gas - additional sales revenue Replace aeration air for blower energy savings at WRRFs

Air Quality Improvement Priority air pollutant, NOx to Non-Detect Algae will assimilate S as secondary macronutrient Lab evidence of VOCs mitigation (as an additional carbon source)

Additional Project Credits Renewable Energy Credits Carbon Credits; Reduces Facility Carbon Footprint Emissions Reduction Credits Grant & Incentive Eligibilities

© 2015 ESSRE Consulting, Inc.

Nutrient Recovery

No P in flue gas – opportunity for Enhanced Phosphorus Removal from wastewater and from other organic waste materials

100% NOx may not be sufficient – opportunity for Enhanced Nitrogen Removal from wastewater

CCU & GHG Mitigation via Microalgae is Independent of Wastewater Treatment OperationsNutrient Pollutants Removed to Improve Water Quality and Reused for Mass Algae GrowthMass Algae Growth is the “N-E-W” Answer for the Nutrient-Energy-Water Nexus

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106CO2 +16HNO3 + H3PO4 +78 H20 C106H175O42N16P + 150O2(light)

Almost half of the algae by weight is C, hence,• 1 Ton of Algae “FIXES” 1.83 Tons of CO2

Algae critical N:P ratio, approximately 16:1

20 Bioreactors will require approximately 50 lbs. per day P

How to supply that P sustainably?:• Extracted from wastewater/digestate liquid effluent• Extracted from landfill leachate• Extracted from animal waste, e.g. Poultry Litter

© 2015 HYTEK-Bio LLC. All rights reserved. | Confidential

• Proprietary conversion process for producing a high Nitrogen (N), high Phosphorus (P) liquid nutrient from Poultry Litter to sustain mass algae growth

• Applied to Poultry Litter, conversion process clarifies a liquid extract and reduces its odor

• Wetted, nutrient-reduced mass used as co-substrate for AD enhancement

• Novel nanomaterials are used to concentrate P from liquids (the above “tea”, landfill leachate, digestate, treated wastewater effluent, compost tea, aquaculture effluent, etc.)

© 2015 HYTEK-Bio LLC. All rights reserved. | Confidential

Bench-scale lab results using nutrient solution derived from Poultry Litter indicate increase algae density from 5 g/L to 10 g/L

Hence, double the GHG CO2 and NOx mitigation effects of s.HTB1 as a result of nutrient extraction and recovery

Additional carbon footprint reductions by avoiding synthetic, commercial fertilizer for algae growth or nutrient addition for biological treatment


Assume 3.3MM gallon swine lagoon and 8632 farm pigs

From UA (Fay.) manure study: For 1- 5% Swine (solids)

• 12.6 lb P2O5 per 1000 gallons of lagoon wastewater

• Or, 5.5 lb P /1000 gallons

• And, 18,150 lb P available in lagoon

Assume 40 lb/day P consumed by algae facility

If no other P introduced, lagoon is P-free after 454 days

Assuming 20 lb P per day fresh excretion and 90% availability of algae facility = net 16 lb P reduction =

1135 days to P-free lagoon wastewater

One milligram of quartz sand

© 2012 Water Environment Federation

100 Micron9 Square cm

1 Micron3 Square Meters

10 nm300 Square

MetersOne Hundred

Trillion ParticlesOne Billion

ParticlesOne Hundred

Particles


C-Fe, solution method,

BET surface area: approx. 400 m2/gC-Fe, powder method,

BET surface area: approx. 425 m2/g

Phosphate Red – MetaMateria


Interconnecting Pore Structure 20-100 nm Nano Crystals Added

“Natural” BioEnergy Sourced from Waste Adds new revenue streams (economic boost to AD projects)

Provides an on-site, “farmed” amount of biomass for co-digestion

Promotes Renewable Energy and Improved Air Quality

Independent of operations ( just “give me the gas”)

Innovative Enhanced Nutrient Reduction Poultry Litter liabilities turned into an asset

Innovative, sustainable alternative to chemically enhanced phosphorus removal

Reduced Facility Carbon Footprint Clean Energy Solution that reduces GHG emissions by MegaTons of CO2 per year

High Value End Products - Neutraceuticals, Pharmaceuticals, Biofuels, High- end Proteins, Bioplastics, etc.

Sustainable Operations: Air Pollutants Converted into “N-E-W Treasures” that are profitable and biodegradable; P removed without the use of chemicals that add to waste sludge

Closes the Carbon loop; Long-term goal is cost-effective biofuels that replace fossil fuels

Robert MrozCEO & President, HYTEK-Bio, LLC

Feng Chen, Ph.D.Director, UMD Environmental Science Center

Tito Viswanathan, Ph.D.Research Chemist, U of Arkansas, Little Rock

Richard Schorr, Ph.D.CEO & President, MetaMateria, LLC


Ed Weinberg, ESSRE Consulting, Inc. (215) 630-0546 [email protected]

Sean Fitzpatrick, AvAer Partners, LLC (703) 216-1206 [email protected]

For Discussion:Microalgae as a co-substrate for manure digesters?Maximizing Farm Digester Gas Production using ag waste materials?What Ag policies to advocate that will promote Algae Farming?Funding incentives available to promote manure AD Co-digestion?

QUESTIONS

MICROALGAE: NEW DRIVERS FOR AD & MANURE VALORIZATION

microalgae: new drivers for ad & manure valorization · microalgae: new drivers for ad &...

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