Algenol s Second Generation Photobioreactor Harlan L Miller III and Algenol Team

Transcription

1 Algenol s Second Generation Photobioreactor Harlan L Miller III and Algenol Team

2 Algenol s Direct To Ethanol Process Our algae utilize 1. CO 2 2. Saltwater 3. Sunlight 4. Inorganic nutrients 2 CO H 2 O C 2 H 5 OH + 3 O 2 To produce liquid biofuels 1. Ethanol 2. Biodiesel 3. Jet fuel 4. Gasoline Direct To Ethanol technology The process occurs in low cost photobioreactors (PBRs) 1. Reactor systems that promote photosynthesis 2. Culture vessels that produce high amounts of ethanol and biomass Direct To Ethanol Commercial Vision 2

3 Three enabling technologies Commercial organism Photobioreactor technology Downstream processing Cyanobacteria: fastgrowing photosynthetic prokaryotes High carbon uptake rates in marine environments Enhanced fermentation pathways to convert carbon to ethanol Robust crop for outdoor cultivation Purpose of this talk is to introduce Algenol s 2 nd generation VIPER TM photobioreactor system They are perfect minigreenhouses for algae Ethanol is separated from media with patented Vapor Compression Steam Stripper Spent biomass is converted into diesel, jet and gasoline via hydrothermal liquefaction Ethanologenic cyanobacteria Generation 1 photobioreactors Integrated Biorefinery 3

4 Photobioreactor Functions Provide enclosed cultivation environment for ethanol-producing cyanobacterial cultures Durable film permits transmission of photosynthetically active radiation (PAR) while blocking potentially harmful ultraviolet radiation Allows for delivery of inorganic compounds necessary to the process Fertilizer nutrients CO 2 Supply mixing and cell movement to: Discourage boundary layer formation around cells Distribute dissolved nutrients within cultures Provide for efficient gas exchange for CO 2 addition and O 2 removal Retains volatile compounds (i.e., ethanol) Provides a barrier between the culture and the external environment Allows for media exchange and culture harvest Inexpensive to build and operate 4

5 1 st Generation Photobioreactors From Algenol deployed horizontally oriented, 8 inch (20 cm) deep, photobioreactors Benefits Inexpensive flexible film tube (low capital costs) Cells mixed with magnetically coupled mixing system (low operation costs) Ethanol harvest through condensate collection Limitations Poor light distribution Culture temperature management Low gas exchange efficiency Productivity potential less than company targets Generation 1 photobioreactors Pontoon Rudder Foil Magnetic coupling HDPE tubing Magnetically coupled mixing system 5

6 Vertical PBR Development Timeline April 17, 2012 PBR Design Team Kick-off May, prototypes developed July, 2012 Prototypes tested with ethanol producing strain September, 2012 PBR Design Gate Review was conducted and vertical PBR (VIPER TM ) was chosen as 2 nd Gen. PBR January, 2013 Placed order to manufacture VIPERs TM February, 2013 Deployed VIPERs TM 400-block at IBR From Team Commissioning to Contract Manufacture in 11 Months June, 2012 Prototypes tested with wild-type algae September, 2012 Prototypes tested with commercial organism October, 2012 Began discussions with several contract manufacturers about constructing VIPERs TM January, 2013 Deployed VIPERs TM 40-block at IBR March 11, 2013 Received first VIPERS TM samples arrive 6

7 2 nd Generation VIPER TM Photobioreactors In early 2012, engineers developed verticallyoriented, flexible-film photobioreactors that optimized the potential of our commercial algae 7

8 2 nd Generation VIPER TM Photobioreactors 1. Better light use efficiency results in vastly improved production rates 2. Vertical systems have better land use efficiency than horizontal systems Vertical PBRs have greater illuminated surface area to footprint surface area Much higher areal productivities because many more cells are getting light More culture is exposed to less intense light More photosynthesis in more compact cultures results in greater volumetric production rates of ethanol and biomass Vertical systems also require less land preparation 8

9 Dissolved O 2 (µm) Temperature (ºC) 2 nd Generation VIPER TM Photobioreactors 3. Peak temperatures are lower in vertical reactors Heat transfer over more surface area per culture volume exposed to ambient air Less greenhouse heating in PBR headspace Less temperature stress during midday photosynthesis results in greater productivity 4. Vertical systems have better gas exchange dynamics Horizontal Vertical Horizontal Vertical Bubble mixing in vertical systems promotes CO 2 delivery and O 2 removal Less dissolved O 2 results in better culture production Time (day) 9

10 2 nd Generation VIPER TM Photobioreactors Verticals are great at optimizing our algae s potential No verticals don t make 250,000 gallons per acre No verticals don t make 25,000 gallons of ethanol AND 15,000 gallons of oils Increased CAPEX is offset by higher productivity 10

11 Gallons of Liquid Fuel 2 nd Generation VIPER TM Photobioreactors PBR design and organism advancements improved outdoor yields consistent with current company goals <$1.2 per gallon ethanol Annual Maximum Liquid Fuel Production Outdoor Productivity (PDU) Outdoor IBR productivity Year of Production 11

12 Process Scale-up in 2013 at the IBR 10 x Scale Up 4000 Module 40 Block 400 Block 4000 Block First Inoculation Feb. 6 First Inoculation Mar. 15 First Inoculation July 19 Plans to operate into

13 Facility Tour October 3, 2013 Commercial Development Campus Fort Myers, Florida 13

14 Algenol Employees Florida Staff Members Berlin Staff Members 14