Sustainable pilot-scale production of carotenoid compounds from the green microalga Haematococcus pluvialis

Transcription

1 Sustainable pilot-scale production of carotenoid compounds from the green microalga Haematococcus pluvialis Paula Pérez-López, Sara González-García, Edward McHugh, Daniel Walsh, Patrick Murray, Siobhan Moane, Gumersindo Feijoo, Mª Teresa Moreira November 25, 2013

2 Contents Introduction to microalgal processes Goal and scope Inventory analysis Environmental impact assessment Conclusions

3 USES OF MARINE RESOURCES Marine biotechnology Why marine resources?

4 USES OF MARINE RESOURCES Marine biotechnology Why marine resources? With more than 70% of the planet s surface covered by water, oceans are probably the most promising habitat to explore for novel microbial biodiversity.

5 USES OF MARINE RESOURCES Marine biotechnology Number of patents Why marine resources? Marine biotechnology is an emergent sector with an estimated global market value of 2.8 billion in 2010 and annual growth of 4.3% during the period Others 6% Chemistry 54% Pharmacology 32% Agriculture 2% Food 6% Cosmetics 1% Period No. patents involving marine resources % patents in marine biotechnological sector Leary et al. (2009). Marine genetic resources: A review of scientific and commercial interest. Marine Policy 33(2):183-94

6 SIGNIFICANCE OF MICROALGAL PROCESSES Products from microalgae MICROALGAE: One resource, many products... Algae Oils Biomass Carbohydrates Proteins From Wilkie et al. (2011). Indigenous algae for local bioresource production: Phycoprospecting, Energy Sustain Dev 15(4):365-71

7 TECHNOLOGICAL OPTIONS Cultivation systems for microalgae How to produce microalgae?

8 Contents Introduction to microalgal processes Goal and scope Inventory analysis Environmental impact assessment Conclusions

9 CASE STUDY Pilot-scale production of carotenoids by H. pluvialis Haematococcus pluvialis Green microalga Green phase Cultivated in two stages It accumulates between 1-5% of astaxanthin Astaxanthin Red carotenoid (pigment) Applications as additive in food industry, cosmetics... Red phase Potential uses in pharmaceutical industry due to its antioxidant, anti-inflamatory and antitumor properties

10 GOAL AND SCOPE DEFINITION Objective of the study Quantification of main environmental impacts associated to the process Cradle-to-gate perspective (from raw materials to extraction of the biocompound) Identification of the most problematic stages End of Life Wild Marine Organism Harvesting Cultivation in Reactor Systems HOT SPOTS Product Use ASSESSMENT Harvesting Proposal of alternative scenarios to improve the environmental profile Distribution Product Formulation Extraction and Purification of Biocompounds

11 GOAL AND SCOPE DEFINITION Functional Unit CULTURE IN TWO PHOTOBIOREACTORS IN SERIES (1000 L tanks, 2-4 g/l biomass) HARVESTING 4 kg of biomass (4-5% astaxanthin) EXTRACTION Supercritical CO 2 Extraction 800 g astaxanthin

12 RAW MATERIALS, WATER & FOSSIL FUELS GOAL AND SCOPE DEFINITION System boundaries AIR, SOIL & WATER EMISSIONS BY- PRODUCT (FERTILIZER) WASTE TO TREATMENT ASTAXANTHIN (10% IN OLEORESIN) WATER SUPPLY CHEMICALS (Nutrients & Solvents) SUBSYSTEM 1: CLEANING OF THE REACTOR REACTOR STERILIZATION (ozonization or chemicals) SUBSYSTEM 2: PREPARATION OF THE CULTURE MEDIUM REVERSE OSMOSIS FILTER UV FILTER ADDITION OF NUTRIENTS AND INOCULUM AIR SUPPLY GROWTH STAGE SUBSYSTEM 3: CULTIVATION SETTLING MACHINERY SETTLING STRESS STAGE SUBSYSTEM 4: HARVESTING SUBSYSTEM 5: EXTRACTION ELECTRICITY BACKGROUND SYSTEM CENTRIFUGATION SPRAY DRYING FOREGROUND SYSTEM SUPERCRITICAL FLUID EXTRACTION

13 Contents Introduction to microalgal processes Goal and scope Inventory analysis Environmental impact assessment Conclusions

14 INVENTORY ANALYSIS Data sources Field data (Surveys to producers) Databases Bibliographic sources GENERAL INFORMATION Partner Objective Production Extraction/Purification Type of marine organism (please tick the appropriate box ) Microalgae Macroalgae Marine fungi and marine protists Scientific name Marine sponges Epiphytic bacteria Bioactive compound Alternative producer/producers of the compound Cultivation method (please tick the appropriate box ) Open raceway ponds Shore base farming Photobioreactor Traditional biofermenter Tubular reactor Tissue culture Other:...

15 INVENTORY ANALYSIS Inputs and outputs INPUTS from TECHNOSPHERE Energy Transport Distance (km) Total electricity from Irish grid 1, INPUTS from kwh TECHNOSPHERE Cleaning of the reactor OUTPUTS to TECHNOSPHERE Materials 1, kwh (OPT. 2) OPTION 1 Lorry, t, Euro tkm 600 Products Chemicals Ship tkm 1400 Cleaning of the reactor OLEORESIN OPTION (10% Cleaning astaxanthin) of the reactor 1 for reactor sterilization 8.00 OPTION kg 2 Lorry, t, Euro tkm 800 OPTION 2 for reactor sterilization OPTION 2 for reactor sterilization Equipments Ship tkm 1400 Pure astaxanthin Tap water (cleaning) 4,009 L Stainless steel kg Reactor sterilization kwh Preparation kg of the culture medium NaClO kg Co-solvent Preparation of the culture medium 7.16 OUTPUTS kg Chemicals to ENVIRONMENT Lorry, t, Euro tkm 600 Preparation Reverse of the osmosis culture filtration medium 7.71 kwh Preparation of Ship the culture medium tkm 1400 Impurities NaNO Water emissions kg kg UV filtration 0.35 kwh Equipments Stainless steel Lorry, t, Euro kg tkm 800 Avoided product K 2 HPO Cultivation (fertilizer) 4 Cleaning of the reactor (OPTION ) Harvesting kg PVC Ship Extraction kg tkm 1400 KH 2 PO Reactor 4 lighting Wastewater 4,009 1, L kwh Wastewater kg Cultivation UV 1, lamps L Wastewater kg 0.93 L Cell paste CaCl 2 Air blowing NaClO kg kwh NaNO kg kg 3 Equipments Polyamide Lorry, g NaNO t, Euro kg tkm mg 800 N fertilizer MgSOAgitation 4 Cultivation kwh K 2 kg HPO 4 kg Cultivation ammonium Ship sulfate, g as KN 2 HPO tkm mg 1400 P fertilizer NaCl Harvesting Wastewater 1, L KHkg 2 PO 4 Harvesting kg Stainless diammonium steel g phosphate, KH PO as 4 P Kg 2 O mg 5 C 6 H 8 OCentrifugation 7 NaNO (harvesting) kwh kg Equipments Reactor lamps Lorry, t, 0.13 Euro Kg tkm 800 Waste treatment g CaCl g CaCl mg C 6 H 5+4y Spray Fe x Ndrying y O 7 K 2 HPO g kwh MgSO kg 4 Harvesting Ship g MgSO tkm mg 1400 Steel, to inert Na 2 Extraction landfill CO 3 KH 2 PO g NaCl kg Extraction kg Stainless steel g NaCl kg mg Polyvinyl chloride, C 10 H 16 Supercritical Nto 2 O 8 sanitary CaCl CO landfill 2 extraction g kwh C kg Chemicals Extraction Lorry, t, Euro tkm H 8 O 7 kg g C 6 H 8 O mg H 3 BO C kg Drying agent Ship kg tkm 1400 Fluorescent lamps, to specific treatment for 6 H 5+4y Fe x N y O C 6 H 5+4y Fe x N y O ZnSO 4 MgSO kg Equipments kg Co-solvent Lorry, t, 4.67 Euro kg tkm 800 electronics wastes g 7 CuSO mg NaCl g Nakg 2 CO 3 Stainless steel Ship g Na CO kg tkm mg 1400 Textiles, to Co(NO municipal 3 ) 2 incineration C 6 H 8 O g C 10 kg H 16 NFinal 2 Okg 8 disposal g C 10 H 16 N 2 O mg FeCl kg Solid waste Lorry, t, Euro tkm 50 Diatomaceous earth, to inert Clandfill 6 H 5+4y Fe x N y kg ZnCl 2 O g H 3 kg BO g H 3 BO tkm (OPT. 2) mg CoCl 2 Na INPUTS kg from ENVIRONMENT 2 CO g ZnSO g ZnSO mg MnCl Preparation of the culture medium 2 C kg Cultivation 10 H 16 N 2 O g CuSO g CuSO mg Biomass inoculum 0.02 kg CO Na 2 MoO 4 H kg kg 3 BO g Co(NO 3 ) g Co(NO 3 ) mg River/rain water ZnSO 2,786 L g FeCl g FeCl mg CuSO g ZnCl g ZnCl mg Co(NO 3 ) g CoCl g CoCl mg FeCl g MnCl g MnCl mg ZnCl g Na 2 MoO g Na 2 MoO mg

16 Contents Introduction to microalgal processes Goal and scope Inventory analysis Environmental impact assessment Conclusions

17 ENVIRONMENTAL IMPACT ASSESSMENT Selected methodology and impact categories Use of LCI results to quantify environmental potential impacts Assignment of impact categories according to CML 2001 method ADP Abiotic depletion POFP Photochemical oxidants formation AP Acidification HTP Human toxicity EP Eutrophication MEP Freshwater aquatic ecotoxicity GWP Global warming MEP Marine ecotoxicity ODP Ozone layer depletion TEP Terrestrial ecotoxicity

18 ENVIRONMENTAL IMPACT ASSESSMENT Characterization results Functional unit = 800 g astaxanthin Impact category Unit Chemical disinfection Ozone sterilization ADP kg Sb eq AP kg SO 2 eq EP kg PO 4-3 eq GWP kg CO 2 eq ODP kg CFC-11 eq HTP kg 1,4-DB eq FEP kg 1,4-DB eq MEP kg 1,4-DB eq TEP kg 1,4-DB eq POFP kg C 2 H 4 eq

19 Relative contributions ENVIRONMENTAL IMPACT ASSESSMENT Relative contribution per stage 100% 80% 60% 40% Cultivation stage 80% of impacts 20% 0% ADP AP EP GWP ODP HTP FEP MEP TEP POFP Cleaning of the reactor Cultivation Extraction Preparation of the culture medium Harvesting

20 Relative contributions ENVIRONMENTAL IMPACT ASSESSMENT Relative contribution per involved activity 100% 80% 60% 40% 20% Electricity >75% of impacts 0% ADP AP EP GWP ODP HTP FEP MEP TEP POFP Water Chemicals Materials Transport Electricity Waste treatment

21 ENVIRONMENTAL IMPACT ASSESSMENT Relative contribution of electricity requirements Aeration in stress stage 2.4% Agitation in stress stage 2.4% Spray drying 4.2% Supercritical fluid extraction 8.0% Reactor lighting in stress stage 58.5% Reactor lighting in growth stage 19.5% Aeration in growth stage 2.4% Agitation in growth stage 2.4%

22 ENVIRONMENTAL IMPACT ASSESSMENT Improvement scenarios How to reduce electricity consumption

23 ENVIRONMENTAL IMPACT ASSESSMENT Improvement scenarios Improvement alternatives Annular PBR with sunlight Flat-panel PBR with artificial lighting Flat-panel PBR with sunlight

24 ENVIRONMENTAL IMPACT ASSESSMENT Improvement scenarios Sc 1 (base case): annular PBR with artificial light and 800 g astaxanthin produced. Sc 2: annular PBR with sunlight and 400 g astaxanthin produced. Sc 3: flat-panel PBR with artificial light and 800 g astaxanthin production. Sc 4: flat-panel PBR with sunlight and 400 g astaxanthin produced.

25 Relative contribution (%) ENVIRONMENTAL IMPACT ASSESSMENT Improvement scenarios Reductions of impact in all proposed scenarios, ranging between 15-75% ADP AP EP GWP ODP HTP FEP MEP TEP POFP Sc. 1: 2 annular, artificial Sc. 3: 2 flat-panel, artificial Sc. 2: 2 annular, sunlight Sc. 4: 2 flat-panel sunlight

26 Contents Introduction to microalgal processes Goal and scope Inventory analysis Environmental impact assessment Conclusions

27 Conclusions Environmental performance of a pilot-scale microalgal process for the production of high value-added molecules was evaluated with LCA methodology. Electricity consumption was identified as the main responsible for the total impacts in all categories, especially due to lighting requirements in the cultivation stage.

28 Conclusions Other steps of the process chain, such as production of chemicals for culture medium, materials for equipment or air supply present secondary contributions in all the assessed impact categories. Results suggest that significant improvements may be achieved by the use of alternative reactor configurations, thanks to the lower electricity requirements of these options.

29 Acknowledgements Sustainable Production of Biologically Active Molecules of Marine Based Origin FP 7 - KBBE Collaborative Project

30 La mer est tout! Elle couvre les sept dixièmes du globe terrestre. Son souffle est pur et sain. C est l immense désert où l homme n est jamais seul, car il sent frémir la vie à ses côtés (Vingt mille lieues sous les mers, 1870)

31 Sustainable pilot-scale production of carotenoid compounds from the green microalga Haematococcus pluvialis Paula Pérez-López, Sara González-García, Edward McHugh, Daniel Walsh, Patrick Murray, Siobhan Moane, Gumersindo Feijoo, Mª Teresa Moreira November 25, 2013