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Microalgae culture for biofuel production Dr Navid R Moheimani BSc, MSc, PhD Chief Scientific Officer Smorgon Fuels Pty Ltd email: [email protected] Fats or Oils + Methanol + Catalyst FAME & Glycerol Our capacity is = 100,000,000 L/y http://en.wikipedia.org/wiki/Image:Mauna_Loa_Carbon_Dioxide.png Methods of CO2 removal (CDR): Injecting liquefied CO2 into the deep sea or burying CO2 underground Biofixation of CO2 by photosynthetic organisms Why Microalgae? • Slow growth of higher plants • High fresh water requirement of higher plants • High cost of land for growing higher plants • No competition with food supply Potential species • There are many marine and freshwater species • Photosynthetic, calcified, etc • High Lipid productivity • High growth rate (45-180 times canola) 1950’s MIT Feasibility tests for CO2 Conversion 1970’s UC Berkeley wastewater treatment systems First commercial open pond algal farms in US US DOE initiates $50 million flue gas/algae program 1980’s UC Berkeley wastewater treatment systems First commercial open pond algal farms in US US DOE initiates $50 million flue gas/algae program 1990’s Japan MITI $200 million bioreactor program (discontinued) German and other EU government programs Commercialization in Australia, Israel, and China; nutraceuticals production exceeds 4,000 tons/year Greenfuel Technology Founded 2001 2001- 2004 design and experimentation 2004: Gen1 deployed at MIT Cogeneration Facility 2005: Gen2 installed at 1000 MW power plant in Southwest; Instigated first International license with The Victor Smorgon Group 2006: Developing coal (NYSERDA) and other applications (eg oil, waste water treatment, etc.) ; Building Gen3 Pilot Project Algae Biotechnology transforms Carbon Management from a Cost into a Revenue Algal Biotechnology Converts Flue Gases & Sunlight into Biofuels through Photosynthesis “Used” Algae have Multiple Potential Uses Cleaned Gases Co-Firing Sunlight Power Plant / Energy Source GreenFuel bioreactor Esterification Flue Gases NOx + CO2 from combustion flue gas emissions Fermentation Green Power Aus$60/t Biodiesel Aus$700/t Ethanol Aus$380/t Protein Meal Aus$400/t Patented Algal Biotechnology Potential Uses for Micro-Algae HARVEST Algae Harvested from Bioreactor DRYING ANIMAL FEED High in Omega 3 Fatty Acids (High Value) OIL SEPERATION Co-Fired for BURNER FUEL (Low Value) BIOGAS Ferment Biomass for ETHANOL Competing with Gas (Low Value) (Equivalent Value to Animal Feed) Digest Biomass Protein Meal ANIMAL FEED denatured by heat (Low Value) Manufacture BIODIESEL (High Value) Aims of Project • Identify suitable species and cultivation system • Optimise the growth on site • Optimise C fixation • Assess economics of large scale culture • Scaling up How to be successful in Algae for biofuel production? Finding algae Finding Photobioreactor Dewatering Post Harvesting Methodologies Na nn Na oc nn hlo Na oc ro nn hlo psi oc ro s s S Sy p hl ps p. ne iru oro is ch lin ps sp oc a p i s . Sp ys lat sp iru tis e n . Sp lin aq sis iru a p uat Sp lin lat ilis iru a p e n Sp lin lat sis iru a p e n lin la sis a te n pl s at is en si Sc C s en hlo ed re e s lla Sp S mu s p iru pir s . lin uli Sp a na An pla . sp a b te n ae si Du Spi na s Ph ae S na rul sp od pi lie ina . ac rul lla s p Pl tylu ina sa . e u m p lin ro tr late a ch ic n ry orn sis Du si u na s c tum lie art lla er sa ae lin a -2 g.m .d -1 Comparison of productivity of microalgae 60 Closed photobioreactors Open ponds 50 40 30 20 10 0 Limits to productivity of Microalgae Physical factors such as light (quality and quantity), temperature, nutrient, pH, O2 and CO2 Biotic factors including pathogens, predation and competition by other algae, and Operational factors such as: shear produced by mixing, dilution rate, depth and harvest frequency Costing of Microalgae CO2 Mitigation The Emissions to Biofuels technology is based on a Profit rather than Cost model Tonnes of CO2 Sequestered per Year / Hectare Carbon-Dioxide Mitigation ($ / ton) 50 700 High Sunlight 40 600 30 500 Kyoto Cost 20 Low Sunlight 400 300 10 Possible Cost in Aust Geoseqestration Potential Trading / Penalty 200 GreenFuel 100 Forest Sequestration GreenFuel Sequestration + + http://www.theage.com.au/news/business/trial-plant-to-transform-emissions-into-biofuels/2006/11/12/1163266412354.html Closed Cycle Biomass Carbon Management Fuel Carbon (100%) Open Cycle Carbon Clean Gases Fuel Carbon (60%) Gross Calorific Value measures 27 MJ/kg for our current microalgae Algae Biomass as Fuel Source (40% Fuel Carbon) Closed Cycle Carbon Management Development Process On-Site Evaluation Phase 1 • Feasibility Unit conducts 3-6 week on-site test for optimal algae production • Field trial requires only slipstream of gas from emission stack Pilot Program Phase 2 Full Scale Phase 3 • Installation of Mini Pilot onto ¼ acre facility • Build out pilot program with modular expansion • Confirmation of all hardware, design, operability with scalability validation • Project optimised for maximum Biofuel yield and ROI • Additional results: Biofuels for internal use Biomax trial at Hazelwood Microalgae selection (on going) Testing flue gas on freshwater and seawater algae Testing the suitability of water resources Measuring productivity Building ESU, floating bioreactor (20-25 g/m2/d) Vertical system (Gen 3) BASED ON 1000 HECTARE 300 tonnes per hectare per annum ACHEIVEMENTS • Engineering Design$ 65% Scale $ Unit Developed, 400 /t Proprietary Meal 78,000,000 • 3D35% Matrix Bioreactor includes equipment for Algal $ setup820 /t Oil $ Harvesting, 86,100,000 Dewatering, and Water Recycling Revenue $ 164,100,000 • Introduction of Bulk Flue Gases Opex $ 173 /t Algae $ 51,900,000 $ 112,200,000 • Consistent Growth Rates achieved at an annualised rate of over 300t per annum of Algal Biomass. EBITDA (not incl. Overheads) • Proved conceptual economic model for Capex v Opex v Growth Rate Capex $ 750,000 1000 hectare $ 750,000,000 • 660 Tonnes of CO2 sequestered per hectare installed ROFE 15% ISSUES • Materials Discovery / Development not adequate for commercial 660,000 CO2 Tonnes Sequestred Rollout Litres of Raw Material for Biodiesel 116,666,667 • Harvesting issues due to materials used for 3D Matrix not releasing Algae easily Tonnes of Protein Meal 195,000 Horizontal system (Gen 4) BASED ON 1000 HECTARE 100 tonnes per hectare per annum ACHEIVEMENTS $ 400 /t Meal $ 26,000,000 • Thin for 35% Film$Bioreactor 820 setup /t Oil includes equipment $ 28,700,000 Algal Harvesting, Dewatering, and Water Recycling Revenue $ 54,700,000 utilising Bulk Flue Gases 65% Opex $ reduced 274 Capex /t Algae • Significantly $ 27,372,009 • Economic Commercial Scale project $ 27,327,991 EBITDA (not incl. Overheads) • Consistent achieved annualised Capex $ Growth 203,696Rates 1000 hectare at$an203,696,000 rate of over 100t per annum of Algal Biomass. ROFE 13% • 220 Tonnes of CO2 sequestered per hectare installed CO2 Tonnes Sequestred ISSUES • Reduced sequestration / growth rates Litres of Raw Material for Biodiesel Tonnes of Protein Meal 220,000 38,888,889 65,000 Uncertainties Microalgae selection Bioreactor geometry Growth rate of microalgae Contaminants Water quality Flue gas quality Weather profile of each site Show video 300 tons algae biomass/ha/y 1/3 of biomass = oil 100 tons of oil /ha/y At Hazelwood = 1000 ha = 100 Mt of oil 1 kg of biomass = 0.5 kg of “C” 27% of CO2 is “C” 555 Kt of CO2 fixed/y 1 Black balloon = 50 g of CO2 BioMax will save 11.1 billion black balloons per year 1L of diesel = 2.67 Kg of CO2 Ref: http://www.epa.gov/otaq/climate/420f05001.htm Biodiesel reduces net emissions of CO2 by 78.45% Ref:NREL/SR-580-24089 UC Category 1503 1L of Biodiesel will save 2.09 Kg of CO2 100 Mega L of Biodiesel will save 209 Kt of CO2 1 Black balloon = 50 g of CO2 Biomax will save 4.2 billion black balloons per year Acknowledgments • The Victor Smorgon Group (Biomax™) • Hazelwood International Power