Industrial application of microalgae in the circular bioeconomy

Transcription

1 Industrial application of microalgae in the circular bioeconomy Dorinde Kleinegris [Applied Biotechnology / Microalgae]

2 Why microalgae? Nutrients (N, P) High areal productivity CO 2 mitigation No arable land Low water use CO 2 Seawater and wastewater Can use residual streams for nutrients High diversity, many products + O 2 [Applied Biotechnology / Microalgae]

3 Products with algae inside Pigments 3 % Ashes 7 % Lipids 20 % Carbohydrates 20 % Proteins 50 % Nannochloropsis [Applied Biotechnology / Microalgae]

4 There is a large gap Microalgae Commodities [Applied Biotechnology / Microalgae]

5 Commercial production: challenges Product costs Scale Production chain analysis Market development [Applied Biotechnology / Microalgae]

6 Biomass Production costs: Model Input Location Netherlands Saudi Arabia Canary Islands Turkish Riviera South Spain Curacao Light Intensity Electricity costs Taxes Labor 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

7 Product costs - biomass production Projections 100ha [Applied Biotechnology / Microalgae]

8 Cost breakdown: cultivation costs [Applied Biotechnology / Microalgae]

9 Sensitivity analysis [Applied Biotechnology / Microalgae]

10 Biomass composition: benchmark on Nannochloropsis N-replete Lipids 20% 50% N-limited SFA * MUFA * PUFA * SFA * MUFA * PUFA * Glyco-, Phospho-lipids 12% 10% 35% 30% 35% Triacylglycerides 2% 37.5% Waxes 3% 1.25% Sterols 3% 1.25% Proteins 50% 30% Water soluble 20% 12% Non-water soluble 30% 18% Carbohydrates 20% 15% Monosaccharides 5% 3% Polysaccharides 15% 12% Pigments 3% 1% Ashes 7% 4% 45% 40% 15%

11 Microalgal biorefinery Pharma Lipids TAG Glyco-lipids Phospho-lipids Waxes Sterols Cosmetic Health care Food additives Food/Feed Microalgae Proteins Carbohydrates Soluble proteins Un-soluble proteins Mono- Oligosaccharides Starch Cellulose Paint, Coating Biolubricant Surfactants Biopolymer Selling price Market demand Pigments Ash/minerals Chlorophyll Carotenoid Phycobilins Bulk chemicals Biodiesel Biokerosene Bioethanol Biobutanol Biomethane

12 Microalgal biorefinery design and techno-economical analysis Biomass productivity Biomass composition Mass and energy balances Utilities cost (energy, labour) CAPEX OPEX

13 Microalgal biorefinery design and techno-economical analysis Microalgal biomass Disrupted Biomass Food/feed I.1) BEADM ILLING III.0) SPRAY DRIER Hexane Isopropanol III.4b) BLEACHING FOR PIGM ENT REM OVAL Hexane Isopropanol 50 C 1 bar 0.4 bar Polar lipids TAG Pigments Waxes 2 C Pigment III.1) LIPID EXTRACTOR Proteins Carbohydrates Ash III.2) DISTILLATION COLUM N FOR SOLVENT RECOVERY Water IV.1) DIAFILTRATION FOR PROTEINS WASHING III.3) DECANTER FOR WAXES REM OVAL non water soluble proteins Waxes Steam Polar lipids TAG Water Ash IV.2) SPARY DRIER FOR PROTEINS/CARBOHYDRATES proteins carbohydrates

14 Microalgal biorefinery design and techno-economical analysis Biofuel Microalgal biomass Disrupted Biomass I.1) BEADM ILLING III.0) SPRAY DRIER Hexane Isopropanol 50 C 1 bar III.1) LIPID EXTRACTOR Proteins Carbohydrates Ash Hexane Isopropanol Water 0.4 bar Polar lipids TAG Pigments Waxes III.2) DISTILLATION COLUM N FOR SOLVENT RECOVERY IV.1) DIAFILTRATION FOR PROTEINS WASHING Methanol 2 C III.3) DECANTER FOR WAXES REMOVAL non water soluble proteins NaOH 2 bar 60 C 30 min III.4) P-14 BATCH / R-101 REACTOR FOR Stoich. TRANSESTERIFICATION Reaction Waxes III.5) EVAPORATION/CONDENSATION FOR M ETHANOL RECOVERY Water 0.4 bar FAME Glycerol Pigments Sterols NaOH Methanol III.6) EXTRACTOR FOR GLYCEROL WASHING H3PO4 FAME Sterols Pigments Glycerol Na3PO4 Water Ash IV.2) SPRAY DRIER FOR PROTEINS/CARBOHYDRATES Proteins Carbohydrates

15 Microalgal biorefinery design and techno-economical analysis Microalgal biomass I.1) BEADM ILLING PEG Phosphate Disrupted Biomass II.6) SPRAY DRIER FOR PHOSPHATE CONCENTRATION II.1) DIRECT PROTEIN EXTRACTOR Phosphate PEG water soluble Proteins Polysaccharides Monosaccharides PEG II.2) BACKWARD PROTEIN EXTRACTOR 1 kda Phosphate water soluble Proteins Polysaccharides Monosaccharides II.3) ULTRAFILTRATION UNIT FOR PROTEIN/POLYSACCHARIDES CONCENTRATION Water 300 kda II.7) DIAFILTRATION UNIT FOR PROTEINS/POLYSACCHARIDES FRACTIONATION II.9) SPRAY DRIER FOR POLYSACCHARIDES PBS buffer 10 kda II.8) DIAFILTRATION UNIT FOR PROTEINS/M ONOSACCHARIDES FRACTIONATION Polysaccharides II.10) SPRAY DRIER FOR WATER SOLUBLE PROTEIN Monosaccharides water soluble Proteins Hexane Isopropanol 50 C 1 bar 1 kda II.4) ULTRAFILTRATION UNIT FOR PHOSPHATE RECOVERY III.1) LIPID EXTRACTOR Hexane Isopropanol Water Polar lipids TAG Pigments Waxes III.2) DISTILLATION COLUM N FOR SOLVENT RECOVERY IV.1) DIAFILTRATION FOR PROTEINS WASHING Methanol 2 C III.3) DECANTER FOR WAXES REMOVAL 0.4 NaOH bar 2 bar 60 C 30 min III.4) P-14 BATCH / R-101 REACTOR FOR Stoich. TRANSESTERIFICATION Reaction Waxes III.5) EVAPORATION/CONDENSATION FOR M ETHANOL RECOVERY Water 0.4 bar FAME Glycerol Pigments Sterols NaOH Methanol III.6) EXTRACTOR FOR GLYCEROL WASHING H3PO4 FAME Sterols Pigments Glycerol Na3PO4 non water soluble proteins non water soluble proteins Ash Water Ash IV.2) SPRAY DRIER FOR PROTEINS non water soluble proteins Complete biorefinery

16 Biorefinery costs

17 Biorefinery costs Cost breakdown

18 Market value of biomass

19 Market value of biomass Cultivation costs South of Spain Biorefinery costs Total costs

20 Market value of biomass Cultivation costs South of Spain Biorefinery costs Total costs

21 Scale - Salmon as example Objective: replace 10% of fish meal with algae 1.26 million tonnes of Atlantic salmon 1.6 million tonnes of feed 0.16 million tonnes of algae Without algae With algae There is a proof of concept

22 Scale - Salmon as example Objective: replace 10% of fish meal with algae 1.26 million tonnes 1.6 million tonnes 0.16 million tonnes Land - County - Area [km 2 ] Norway - only land Productivity: (57*) ton ha -1 y -1 solar conditions Norway / greenhouse + illum days cultivation per year Hectare needed: ha km 2 Current scale worldwide: ~ ha Østfold Akershus Oslo 454 Hedmark Oppland Buskerud Vestfold Telemark Aust-Agder Vest-Agder Rogaland Hordaland Sogn og Fjordane Møre og Romsdal Sør-Trøndelag Nord-Trøndelag Nordland Troms Finnmark Bergen 446 Sotra 179 Algae Needed for feed

23 Main inputs in the process To produce 1 ton of algal biomass: 1.8 tons of CO 2 is needed 0.09 ton N 0.01 ton P micronutrients H 2 O CO 2 Nutrients (nitrogen, phosphor) [Applied Biotechnology / Microalgae]

24 Scale - Salmon as example Objective: replace 10% of fish meal with algae 1.26 million tonnes 1.6 million tonnes 0.16 million tonnes Nutrients needed: tons CO ton N ton P TCM captures ton CO 2 per year Yara produces in Norway alone 2,7 million ton NPK yearly BUT There are other sources as well...

25 Insects Municipality Biodegradable Waste Insect manure CO 2 CO 2 Fish manure

26 Municipality Biodegradable Waste First experiments Insect manure Fish manure

27 We need: Product costs Scale Production chain analysis Market development More robust strains a.o. higher productivity, temperature range Smart production chain Integration with waste streams Market development products [Applied Biotechnology / Microalgae]

28 Conclusions Microalgae can be used for food/feed/chemicals and fuels as a by-product Decrease of costs and increase of scale necessary E.g.: grow on various residual streams They form a perfect link between the bioeconomy and the circular economy [Applied Biotechnology / Microalgae]

29 Tusen takk! Spørsmål? [Applied Biotechnology / Microalgae]