Towards industrial products from microalgae

Transcription

1 Towards industrial products from microalgae Maria Barbosa, Ruiz J, Olivieri G, de Vree J, Bosma R, Willems P, Reith H, Eppink MHM, Kleinegris DMM, Wijffels RH Wageningen University, The Netherlands

2 Develop this process is a sustainable and economical way within the next years Challenges Product costs Scale Product

3 Translate fundamental research to applications Compare technologies Develop process strategies Reduce production costs Acquire knowledge for scaling up Acquire data for projections

4 Bridging the gap from lab to outdoors Where is my Photosynthetic Efficiency????? PE = 3.3 PE = 6.5 Where is my product yield PE TAG < 1 PE TAG = 3

5 Biomass Production costs: Model Input Location Netherlands Saudi Arabia Canary Islands Turkish Riviera South Spain Curacao Light Intensity Electricity costs Taxes Output / Kg biomass Cultivation System CAPEX & OPEX NER Empirical data Sensitivity Analysis Specific parameters Culture temperature Daily Dilution Mixing day/night) Operation days per year... Areas to focus

6 Projections: 100 ha, Flat panel Input Location South of Spain Cultivation system Flat Panel Area of culture 100 Ha Land Rented land Photosynthetic efficiency 3.3 of facility to inocul. 10 Operation days per year 300 days Mode of operation Chemostat Daily dilution 27 Daily dilution in summer 27 Temperature control Yes: Cooling tower Maximum culture temperature 30 C Nitrogen source Urea Phosphorus recycling rate 0 Nitrogen recycling rate 0 Source of CO 2 Commercial No Air flow 0.32 vvm Air flow (night) 0.32 vvm 1.52 Photovoltaic energy No Output BIOMASS COST (no CO 2 incentive) 4.17 kg -1 BIOMASS CAPACITY 7448Ton Yr -1 NER 0.72 CAPEX 10.55M Yr -1 OPEX 20.48M Yr -1 Initial investment 153.8M 5 Wastewater treatment 4 Energy 26 Utilities 1,2 Others 11 Consumables 2 Construction and other fixed costs 27 Raw materials 17 Major Equipment 7

7 4.17 /Kg Temperature control Input Yes: Cooling tower Output BIOMASS COST (no CO 2 incentive) 4.17 kg -1 BIOMASS CAPACITY 7448Ton Yr -1 NER 0.72 CAPEX 10.55M Yr -1 OPEX 20.48M Yr -1 Initial investment 153.8M 5 Wastewater treatment 4 Others 11 Construction and other fixed costs 27 Major Equipment 7 Energy 26 Raw materials 17 Utilities 1,2 Consumables 2

8 4.17 /Kg 3.21 /Kg Input Yes: External Source Temperature control 25 Output BIOMASS COST (no CO 2 incentive) 3.21 kg -1 BIOMASS CAPACITY 7448Ton Yr -1 NER 1.55 CAPEX 8.47M Yr -1 OPEX 15.45M Yr -1 Initial investment 123.1M Wastewater treatment 5 6 Energy 15 Others 13 Major Equipment 7 Construction and other fixed costs 29 Utilities 0,0 Consumables 3 Raw materials 22

9 4.17 /Kg /Kg 2.71 /Kg Input Yes: External Source Temperature control 10 Output BIOMASS COST (no CO 2 incentive) 2.71 kg -1 BIOMASS CAPACITY 7448Ton Yr -1 NER 1.61 CAPEX 5.42M Yr -1 OPEX 14.79M Yr -1 Initial investment 78.1M Wastewater treatment 6 7 Others 12 Major Equipment 5 Construction and other fixed costs 22 Energy 18 Raw materials 26 Utilities 0,0 Consumables 4

10 4.17 /Kg /Kg /Kg 2.60 /Kg 38 Temperature control Maximum culture temperature Input Output Yes: External Source >45 BIOMASS COST (no CO 2 incentive) 2.60 kg -1 BIOMASS CAPACITY 7448Ton Yr -1 NER 1.63 CAPEX 4.75M Yr -1 OPEX 14.63M Yr -1 Initial investment 68.2M C Wastewater treatment 6 7 Others 12 Major Equipment 5 Construction and other fixed costs 22 Energy 18 Raw materials 26 Utilities 0,0 Consumables 4

11 4.17 /Kg /Kg /Kg /Kg Input Photosynthetic efficiency 3.3 -> 6.0 Output BIOMASS COST (no CO 2 incentive) 1.65 kg -1 BIOMASS CAPACITY 13542Ton Yr -1 NER 2.96 CAPEX 4.75M Yr -1 OPEX 17.57M Yr -1 Initial investment 68.2M 1.65 /Kg 60 Wastewater Major treatment Equipment Others 13 Construction and other fixed costs 17 Energy 16 Raw materials 35 Consumables Utilities 3 0,0

12 Sensitivity Analysis 0.53 /Kg dw Example for flat panels in South Spain Done for raceway ponds & tubular at 6 locations Can be extended to other systems, locations and scale

13 Economy of Scale 1,10 and 100 ha Production costs /Kg DW Economy of Scale Thailand Plant area (ha)

14 Economy of Scale 1,10 and 100 ha BREAKDOWN BIOMASS COST Energy 1.3 Utilities 1 Wastewater treatment 1 Consumables 0 Production costs /Kg DW Raw materials Others Utilities 3 Wastewater treatment 4 8 Energy 5.8 Consumables fte Capital costs 63 BREAKDOWN BIOMASS COST Others 15 Raw materials 15 Economy of Scale Thailand Capital costs Plant area (ha) Utilities 5 Wastewater treatment 6 Others 12 2 Energy 9.5 Consumables 5 BREAKDOWN BIOMASS COST 18 fte 32 fte Raw materials Capital costs 35

15 Algae production Many new inititatives at pilot, demonstration and production scale > 100 production companies in Europe Increased production capacity Product development Necton Secil Archimedes and F&M

16 Case 1. Aquafeed? Objective: replace 10 of fish meal with algae 1.26 million tonnes of Atlantic salmon 1.63 million tonnes of feed 0.16 million tonnes of algae AlgaePARC Bonaire 4000 ha salinas 100 ton algae/ha/year 400,000 tons of algae/year 25 of global need for fishmeal for salmon

17 Case 2: Biofuels AlgaePARC Bonaire Feasibility study 4000 ha salinas 100 ton algae/ha/year 33 ton fuel/ha year : ton fuel /year Dream: 50 ton fuel /ha/year tons of fuel/year TUI uses tons kerosene per year 2136 return flights to Bonaire

18 Conclusions Techno-economical model is a powerful tool to assess business opportunities and guide research programs There are business opportunities for microalgae More products should be developed with algae inside Future research will result in Further decrease in production costs Up-scaling