BIOFAT. Business Plan for a 10 ha production plant. European Algae Roadmap Conference 2016 Algae Based Industry Olhão, 7 th April 2016

Transcription

1 BIOFAT Business Plan for a 10 ha production plant European Algae Roadmap Conference 2016 Algae Based Industry Olhão, 7 th April 2016 Project funded under the 7 th Framework Programme FP7-ENERGY GA No Diana Fonseca diana.fonseca@algafuel.pt

2 The Call BIOFAT BIOfuel From Algae Technologies Project nr Call identifier FP7-ENERGY Funding scheme Collaborative project BIOFAT is a microalgae-to-biofuel FP7 demonstration project that integrates the entire value chain of algae process from optimized growth, starch and oil accumulation, to downstream processing (biorefinery) including biofuel production. The BIOFAT approach integrates and scales up complementary technologies and skills from each partner into a global multidisciplinary project. BIOFAT is part of the Algae Cluster together with two more projects 2/33

3 Algaecluster

4 The Consortium 4/33

5 The Concept BIOfuel From Algae Technologies Demonstration Project microalgae to biofuel Production area: 10 ha CO 2 : non-fossil origin Production strategy PBRs for inoculum production Raceways for biomass production and accumulation of oil (Nannochloropsis) or carbohydrates (Tetraselmis) Harvesting: pre-concentration and centrifugation Biofuel: Conversion of oil into biodiesel: transesterification Conversion of carbohydrates into bioethanol: fermentation Sustainability: Developing the concept of algorefinery Budget: 11 M Duration: 4+1 years Partners: 10 < The contract Requirements < The technological solution (state-of-the-art) < The integration 5/33

6 The Concept Main goals Strain selection, in accordance with biofuel production targets, biorefinery concept, environmental conditions and sustainability criteria Optimization of the culture conditions, adoption of strategies for the accumulation of high oil/starch concentrations Partners State-of-the-art technology integration and optimization: combining proven designs of photobioreactors and raceways, with new improvements Minimizing investment and operational costs for successfully scaling-up (20 x 0.5 to 10 ha) the technology developed: low risk scaleup approach Development of an efficient and low energy consumption harvesting strategy: combined filtration + centrifugation Development of the algorefinery concept valorising different co-products from the algae biomass fractions Partners expertise! 6/33

7 The Concept Implementation Proxy for productivity based on real numbers of 1 year operation in 3 different locations Raceway pond, Pilot Plant Camporosso, Italy Low risk scale-up approach: modular approach Business Case for a 10 ha DEMO plant Raceway ponds at prototype plant, BGU, Israel LCA for a 10 ha DEMO plant 7/33

8 The Concept Main challenges Reduce the CAPEX at the industrial level Reduce the OPEX at the industrial level Reduce the risk of scale-up Base the business case scenarios on real and large scale production data Produce biofuels with a positive financial and environmental balance Identify low cost strategies for harvesting and biorefinery 8/33

9 The Concept BIOFAT Strains Tetraselmis suecica F&M-M33 Nannochloropsis oceanica F&M-M24 9/33

10 The Concept Biorefinery Algae Biomass (Nannochloropsis) Microalgae biorefinery #1. Biofuel approach #2. Fine chemical/ nutrients approach Algae valorisation Oil extraction and conversion to biodiesel Lipids (excl. EPA) EPA Algae biomass 1 Value-added processing process o Algae oil refinement o PUFA enrichment o EPA purification o Customised formulas Protein & Carbohydrates 2 Diversified product markets o Human nutrition o Animal feed o Pharmaceuticals o Energy Biodiesel feedstock Protein PUFA EPA 3 Strong market demand o Declining fish stocks o Aging populations o Increased demand for Omega-3s and premium pet food 10/33

11 Pilot Plants BCPP 0.5 ha plant Inoculum for growth Nutrients dilution for starvation Inoculum section: GWP-II reactors 500 m m 3 Growth RWP A : 2x 500 m 2 each ~7 cm depth Starvation RWP B : 2x 1250 m 2 each ~7 cm depth Patent WO2011/ (F&M) 11/33

12 Pilot Plants BCPP CHP unit vegetable oil 12/33

13 Pilot Plants BCPP 13/33

14 Pilot Plants BCPP Raceways design Optimized raceway design Low energetic consumption Only 7-10 cm culture depth Low cost solution 14/33

15 Pilot Plants BCPP Raceways design Concrete special design sump for high torque Paddle Wheels Nominal depth is 15 cm but operating at 7 cm (A&A, UNIFI, F&M) 15/33

16 Pilot Plants BCPP Main achievements Nannochloropsis oceanica F&M-M24 Inoculum production in GWP -II Growth in nutrient replete medium in 530-m 2 RW Nutrient starvation in 530-m 2 RW Tetraselmis suecica F&M-M33 Inoculum production in GWP -II Nutrient starvation in 530-m 2 RW Late summer 16/33

17 Pilot Plants BPPP 0.5 ha plant Inoculum for growth Inoculum for growth Inoculum section: GWP 3 m 3 Growth section: TPBRs Total 48 m 3 Growth section: CRWs 180 m 3 17/33

18 Pilot Plants BPPP Cascade Raceways Nannochloropsis: 4 g DW/L Diana Vítor Fonseca Verdelho Vieira A4F Senior A4F Project Engineer vvv@a4f.pt 5 th Conference of ISAP 2014 June 25 th 18/33

19 Pilot Plants BPPP Cascade Raceways 2 CASCADE RACEWAYS CRWS TOTAL AREA: 3000 M 2 TOTAL VOLUME: 200 M 3 CHANNELS LENGTH: 75 M ABILITY TO PROTECT THE CULTURE FROM ADVERSE CONDITIONS! CHANNELS WIDTH: 10 M Diana Vítor Fonseca Verdelho Vieira A4F Senior A4F Project Engineer vvv@a4f.pt 5 th Conference of ISAP 2014 June 25 th 19/33

20 Improvement RWs Achievements: Lower ratio volume/area Reduction of the operation volume (BCPP 7 cm, BPPP 3 cm) Increased volumetric productivity g/l/day in proportion to the volume reduction Lower costs of dewatering and overall volumes management => Lower energetic consumption (RW + harvesting energy) Higher concentration of the biomass => Better culture conditions and quality => higher annual productivity 20/33

21 Pilot Plants BPPP Main achievements 21/33

22 Productivity (g/m2/d) Pilot Plants BPPP Main achievements Solar Radiation vs Productivity for all Systems TPBR CRW (60%) Solar Radiation (MJ/m2) 22/33

23 Pilot Plants BPPP Main achievements Cultivation in 30 m 3 TPBR Continuous production for 33 days Jun-Jul Optimized culture medium 95% recirculation Average surface productivity: g.m -2.d -1 23/33

24 DW (g/l) Pilot Plants BPPP Main achievements Cultivation in CRW with different pump frequencies CRW, Nov 2014, Pump Frequency 30 vs 37.5 Hz Culture Days DW (g/l) - CRW_1 (75%) DW (g/l) - CRW_2 (60%) Average productivity: 2.2 x higher with higher frequency Energy consumption: 1.9 x higher with higher frequency 24/33

25 Biomass composition Main achievements Nannochloropsis oceanica F&M-M24 Fatty acids/epa average content: N-replete medium N-depleted medium TFA (g/g dw) % PUFA (g/g DW) % EPA (g/g dw) % Protein (g/g DW) % Tetraselmis suecica F&M-M33 Fatty acids/epa average content: N-depleted medium Carbohydrate (g/g dw) % 55.0 Protein (g/g DW) % 21.0 Lipids (g/g dw) % 15.0 Carotenoids (g/g dw) % 0.2 Vit E (g/g dw) % /33

26 Harvesting Strategy Production 1-4 gr/l Pre-concentration 1-4 % Harvesting % Culture medium recycling 26/33

27 Downstream Processing Top Layer (lipids) Nannochloropsis Biomass + Solvent Milling Separation Supernatant (proteins + lipids) Bottom Layer (Proteins) Top Layer (lipids) Tetraselmis Biomass + Solvent Milling Separation Supernatant (Proteins) Bottom Layer (Carbohydrates) 27/33

28 LCA Sustainability is at the center of the BIOFAT project LCA tool being developed by Abengoa in coordination with Algae Cluster Process evaluation from environmental, economic and social points of view First version already in validation for the pilot units which are running Validated version to be applied to the DEMO => key point for investment attraction 28/33

29 The DEMO PLANT Main assumptions Sufficient land size: the plant is designed to host equipment covering more than 10 ha of production area Proximity to water source: the plant will require a supply of saltwater, as such the plant needs to be located near a freshwater, brine or seawater source. Sufficient solar radiation: average value for South Europe annual radiation - 19 MJ.m -2.d -1 Source of CO 2 in the vicinity: a nearby source of CO 2 is required to meet the microalgae culture s carbon requirements. This requirement can be met by having an industry complex nearby capable of supplying sufficient flue gas (which will require treatment). Local talent pool: the plant should be located in the vicinity of education institutions such as universities in order to secure a long-term talent supply; Operation period: The plant will operate for 350 days a year, considering 15 days of stop for maintenance during the winter period. 29/33

30 Products Production systems Input systems The DEMO PLANT - Nannochloropsis Key OS01. Seawater supply OS02. Nutritive medium supply OS03. Carbon supply Flue gas OS07. Temperature regulation Input flows Production flows Effluents recycling flows OS04. Culture production (Laboratory) OS05. Inoculum production (GWPs) OS05. Culture production (RWs) OS06. Culture induction (RWs) OS08. Harvesting system OS09. Drying OS09. Downstream Processing OS09. Drying OS10. Medium recycling and effluents Superfood (rich in protein and PUFA) Biodiesel Biofertilizer Notes: OS01-OS10 are the operating system units of the plant GWP = Green Wall Panels RW = Raceways OS11. Data acquisition and Control; OS12. Offices, civil infrastructures 30/33

31 The DEMO PLANT Nannochloropsis oceanica F&M-M24 45% TFA CAPEX distribution 2% 3% 0% 0% 1% 1% 9% 4% 1% 7% 14% 16% 0% 42% S01 - Water treatment S02 - Nutritive medium S03 - Carbonation S04 - Laboratory S05 - GW and PBR S06 - Raceways S07 - Thermal regulation S08 - Harvesting S09 - Processing S10 - Effluents, water recicling and cleaning S11 - Control and electric systems S12 - Office, warehouse and workshop Civil Other costs 31/33

32 The DEMO PLANT Nannochloropsis oceanica F&M-M24 45% TFA OPEX distribution MANPOWER 27% 35% ELECTRICITY MAINTENANCE NUTRIENTS 4% 9% 2% 4% 19% REAGENTS CONSUMABLES OTHER 32/33

33 The Next Steps BIOFAT Business Cases: several scenarios will be designed for a 10 ha plant DEMO - with real data Tetraselmis BPPP, Portugal Biofuels Nannochloropsis BCPP, Italy Biorefinery Biofuel production trial More interesting Business Case: investment opportunities 33/33

34 Dissemination

35 Dissemination

36 THANK YOU! 36/46