Open-Raceway Algal Production Operations - Algae...
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Transcript of Open-Raceway Algal Production Operations - Algae...
Open-Raceway
Algal Production
Operations
September 2014
Dave Hazlebeck
The views expressed are those of the author(s) and
do not reflect the official policy or position of the
Department of Defense or the U.S. Government.
Distribution Statement “A” (Approved
for Public Release, Distribution Unlimited)
Distribution Statement “A” (Approved
for Public Release, Distribution Unlimited)
Global Algae Innovations
Founded in December 2013 to produce algae for
Protein, Biofuel, and High Value Products
Distribution Statement “A” (Approved
for Public Release, Distribution Unlimited)
Global Algae Innovations
Focused on Low-Cost Production Technology
• Suite of advances throughout the process
• Economical process for biofuels iis within reach
• Novel, inexpensive photobioreactor
Operating 33-acre algae facility in Kauai
• Scalable system design with integrated harvesting, dewatering, and drying
• CO2 supplied from off-gas of adjacent power plant
• Large-scale open system operated with negligible contamination
Partnerships for application to high value products
• Strain development
• Established distribution channels
• Specialized unit operations
Teaming on Government R&D Projects
• Teams include universities, government laboratories, technology providers, testing facility owners, and product end users
Distribution Statement “A” (Approved
for Public Release, Distribution Unlimited)
33-Acre Kauai Algae Facility
Distribution Statement “A” (Approved
for Public Release, Distribution Unlimited)
Largest Raceway is 3.2 Acres
Distribution Statement “A” (Approved
for Public Release, Distribution Unlimited)
• Constructed in 2011 and operated until March 2012
- Scalable raceway design, high algal concentration and high productivity
- Large-scale open system with negligible contamination
- Round the clock carbon dioxide supply from power plant effluent with low pressure drop on the gas
- Mechanical dewatering to over 30% solids and full media recycle
• Idle from March 2012 to March 2014
• March 2014 to Present
- Repairs and retrofits completed
- Fully operational with improved capabilities
Kauai Algae Facility History
Distribution Statement “A” (Approved
for Public Release, Distribution Unlimited)
Permanent Connection to Power Plant
Stack for CO2 Supply
• All CO2 for growth from adjacent
power plant stack
• 24 hour per day CO2 recovery
• Power plant off-gas returned to
stack after CO2 recovery
Distribution Statement “A” (Approved
for Public Release, Distribution Unlimited)
Raceway System is Fully Operational
Raceway System Repair and Retrofits
• Small raceways started in March
• Larger raceways started in June
after power plant connection
• Improved data acquisition and
control system
• Cultivated a number of strains
- chlorella
- scenedesmus
- Diatoms
- Cyanobacteria
Distribution Statement “A” (Approved
for Public Release, Distribution Unlimited)
New Harvesting, Dewatering and Drying
System Fully Operational
Distribution Statement “A” (Approved
for Public Release, Distribution Unlimited)
Fully Integrated Harvesting,
Dewatering and Drying
• Dewater to ~30% solids
• Dry to 94% solids
• Fully integrated operation from
harvest through dry material
Distribution Statement “A” (Approved
for Public Release, Distribution Unlimited)
Membrane Permeability Independent of
Algae Concentration
0
100
200
300
400
0 1 2 3 4 5 6
Mem
branePerm
eab
ility,LMH/TMP
RetentateAlgae(g/L)
TestCondi ons:6000litersprocessedAlgaecollec onefficiency~99.4%
Distribution Statement “A” (Approved
for Public Release, Distribution Unlimited)
Starting 12 Month Continuous
Operational Test This Fall
Cultivation
• C, N, P balance
• Productivity
• Weather
• Microscopy
• Flow cytometer
• Oil and protein content
Unit Operations
• Yield
• Product quality
• Energy use
• Efficacy
Distribution Statement “A” (Approved
for Public Release, Distribution Unlimited)
Opportunities for Collaboration During
the Operational Test
• Collect samples for additional data on fully characterized system,
e.g. qPCR, transcriptomics, FlowCam, areal spectrophotometry
• Slip streams and area for piloting of new harvesting,
dewatering, or drying technologies
• Algae biomass for extraction testing
• Excess algae meal for feed, polymer, or other product trials
Distribution Statement “A” (Approved
for Public Release, Distribution Unlimited)
Current Collaborators
TSD Management Associates