ALGAE Upscaling and costs
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Transcript of ALGAE Upscaling and costs
10/29/2008
1
Biodiesel from microalgae
René H. Wijffels
www.bpe.wur.nl
Contents
� Biofuels� Truth about microalgae� Production methods� Feasibility study� Our microalgae research agenda� Biorefinery of microalgae� Demonstration� Conclusions
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Biofuels
� Botryococcus� Alkanes (C34) � High concentrations (40/70%)
� Other algae� 20/60% lipids
� High productivity� Palm oil: 6,000 l/ha/year� Algae: 20,000/150,000
l/ha/jaar� No competition with food� Salt water
� Investmens in US: US$ 2.4 billion (NYTimes)
Many new companies� A2BE Carbon Capture� Algaelink� Algoil� Aquaflow Binomic Corporation� Aquaflow Bionomics� Aquatic Energy� Aurora Biofuels� Blue Marble Energy� Bionavitas� Circle Biodiesel & Ethanol
Corporation� Enhanced Biofuels &Technologies� GreenFuel Technologies� Greenshift
� Green Star Products� Infinifuel Biodiesel� Inventure Chemical� LiveFuels� OriginOil� PetroAlgae� PetroSun� Seambiotic� Solazyme� Solena Group� Solix Biofuels� Texas Clean Fuels� Valcent Products� Vertical Algae Biofuel Growing
Truth about algae
Lipid content algae is 20-60%
0
50
100
150
200
250
300
Ponds Tubular Flat panel Theoreticalmaximum
Bio
mas
s p
rod
uct
ivit
y (t
on
ha
-1 y
r-1)
Eindhoven
Bonaire
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Production methods of algae
� Open systems� Raceway
� Cheap?
� Closed systems� Bubble column
� Tubular reactors
� Flat panels
� Expensive?
Open systems: raceway ponds
� Open
� Mixing via paddle wheels
� System that is used most
� Low investments costs
� Limitation in CO2 supply
� Productivity 20 tonnes. ha/1. year/1
� Biomass concentration <0.5 g/l
� High costs for harvesting
Cyanotech (Hawaii), 75 ha
Bubble column
� Closed
� Mixing via air and CO2
� Productivity 50 tonnes. ha/1. year/1
� Biomass concentration 2 g/l
� Hard to scale up (forest)
ECN, 70 l
Wageningen Univ, 70 l
Mario Tredici, Univ. Florence
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Tubular reactor
� Closed
� Mixing via air and CO2
� Productivity 60 tonnes. ha/1. year/1
� High surface/volume ratio
� Biomass concentration 3 g/l
� Accumulation oxygen
� Scalable
Algatechnology, Israel
Technogrow/LGem, Made
Tubular reactor + dilution of light
� Tubular reactor
� Dilution of light
� 1.2 ha
� Klötze (Germany)
� Productivity 80 tonnes. ha/1. year/1
+ + +
Bioprodukte Prof. Steinberg Produktions/ und Vertriebs GmbH
Flat panel reactor
� Intensive mixing
� Short light/dark periods
� High biomass concentrations (>15 g/l)
� Productivity 100 ton. ha/1. year/1
� Scalable?
Ben/Gurion Universiteit, Israël
Wageningen University
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Feasibility study Delta nv
Horizontal tubes
Raceway ponds
Flat panels
Tubular reactor
Degasser25 %
Headspace
StackgasCO2
Solar collector
Centrifuge
Pump
Harvesttank
Biomass
NutrientInlet
T
pH
DO
Monitor and ControlUnit
Stack gas/CO2
Degasser25 %
Headspace
StackgasCO2
Solar collector
Centrifuge
Pump
Harvesttank
Biomass
NutrientInlet
T
pH
DO
Monitor and ControlUnit
Stack gas/CO2
Biomass production costs horizontal tubular reactor
� 1 ha plant� 10.62 €/
kg biomass
� 100 ha plant� 4.02 €/
kg biomass
� 150 €/GJ
� Present value� 10 €/GJ
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
Buildings Polyethylene tubes Photobioreactor Culture medium
Carbon dioxide Media Filters Air f ilters
Pow er Labor Payroll charges
Maintenance General plant overheads
Power 42%
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Sensitivity analysis
-100 -90 -80 -70 -60 -50 -40 -30 -20 -10 0
Culture medium for free
CO2 for free
Both CO2 and medium for free
Dilution rate 10% v/v per day
Photosynthetic Eff iciency 5%
CO2 incentive (15 € / ton CO2)
No centrifugation
PE 5%; CO2 and medium for free, CO2 incentive
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
% Decrease in production cost
Biomass production cost
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
Buildings Polyethylene tubes Photobioreactor Culture medium
Carbon dioxide Media Filters Air f ilters
Pow er Labor Payroll charges
Maintenance General plant overheads
4.02 € / kg biomass
10.62 € / kg biomass
0.4 € / kg biomass15 €/GJ
89% decrease
1 ha
100 ha
potential
Labor 28% Power 22%
Power 42%
Comparison of systems (100ha)
Circulationpump 46%
Air blowers24%
Centrifuge15 %
%Main contributor to
biomass production cost
4.024.035.70€ / kg DWBiomass production cost
341938647M€ /haInvestment
2967157692180180m3Culture volume
303010%Daily dilution rate
0.0340.030.2mLight path
351.5%Photosynthetic Efficiency
414163632071ton /yearBiomass Production
Horizontal tubular reactor
Flat panel reactor
Raceway pond
Units
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Research programs
� Photosynthetic Cell Factories (NWO)
� Solar/H and Solar/H2 (EU)
� Sealand Sole (Min. Agriculture, province Sealand, companies)
� IWT: collaboration with University of Ghent
� Proviron
� EOS/LT (Akzo, Ingrepro, Essent)
� Wetsus (13 companies)
WETSUS research project
� Feasibility study as basis� Aim: reduction of production costs� Biofuel is not the only product� Several breakthroughs needed to realize
economical feasibility� Joining forces� Basis for demonstration projects� Technological Top Institute; funding
� 25% university (Wageningen University)� 25% companies� 50% government
� 13 companies� 5 million €
Participating companies� AF&F� Dow Chemicals� Delta� Eneco Energie� Essent� Friesland Foods� Hednesford� Ingrepro� Landustrie� Neste Oil� Nuon� Rosendaal Energy� Syngenta
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Research topics
� Energy for mixing
� Productivity/photosynthetic efficiency
� Lipid productivity
� CO2 fixation
� O2 production
� Make use of residual nutrients
� Harvesting
� Extraction
� Production scenarios
Biorefinery of microalgae
� Assumption: 1,000 kg of microalgae� Production costs: 400 €� Production plant
� CO2 fixation: 1,800 kg: /35 €� Nutrient removal from waste: / 65 €� Use of waste heat: /� Production of pure O2: 1,600 kg 50 €
� Product isolation � Lipids for chemistry: 100 kg 200 €� Lipids for fuel: 300 kg 150 €� Proteins for food: 100 kg 500 €� Proteins for feed: 400 kg 300 €� Polysaccharide fractions: 100 kg 100 €
� Summary� Total costs: 300 €� Total income: 1,300 €
Development plans
� Fundamental research is taking place
� We look for further expansion of that
� We wish to demonstrate feasibility� Production
� Product isolation: protein, lipid and polysaccharide fractions
� Supply of biomass for product isolation
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Objectives of pilot/demo plant phase
� Development of a process chain
� Experience with systems
� Information for design of full scale plants
� Comparison of systems
� Comparison of strains
� Comparison of feeds
(nutrients, CO2, sunlight…)
� Supply of biomass for
further processing
� Further processing
Conclusions
� Production of chemicals and biofuels feasible
� Productivity high and no competition with food production
� Technology not ready
� Join forces
� Combination of applications
www.bpe.wur.nl
© Wageningen UR