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Algae Photobioreactor Design Considerations for Commercial
Scale Production
Presented by:Greg Karr
State of the Industry(Algae Farming)
Current
Future
Traditional Farming: 50 – 70 years Algae Farming: 5-7 years (so far)
1930’s Farming or 2009 Algae
Current• Crops can and are
grown and harvested• Require high inputs per
yield, labor/energy• Large scale operations
not feasible or even possible
Future • Equipment improvements will
increase yields and decrease production costs
• Production methods will continually be refined and made more efficient
• Biotech will drive yields up and increase value of specific products
Assumption: Algae industry stays alive
Open Pond
• Lower tech, well known technology
• Lower capital costs• Lower operational and
maintenance costs
• Limited ability to control•Temperature (low side)•Species selection•Seasonal flucuations•Evaporation losses
• Lower production rates, yields and product value• Production rates and product values do not offset costs (under normal conditions)
MRI Florida raceway open pond
Closedloop PBR’s
• Higher tech, generally unproven
• Much higher capital costs• Higher operational costs
and maintenance costs• Offers higher level of
control•Temperature (low side)•Species selection•Evaporation losses
• Offers potential for higher production rates and higher value products• Billion $ question: Can the higher production rates ever justify the extremely large capital and operational costs?
MRI KC AlgaeLink PBR, 3500 L
Capital CostsUnit basis ($ cost/$ revenue)
Higher
Investment Risk
Land Usage
Light Collection
Service Life
Production Controls
Productivity
Product Value (species selection)
Lower
Operational CostsUnit basis ($ cost/$ revenue)
Higher
Labor
Maintenance
Utilities
Water source
Growth Nutrients
Gas input (source and energy)
Culture Maintenance
Lower
Revenues
Adding Value
Biomass Combustion
Animal Feed
Algal Oil
Liquid Biofuel Feedstocks (starches/celluloses)
High Value Compounds
Waste reduction (water/fertilizers)
CO2 mitigation
Lower Value
Issues Not Discussed Here
• Harvesting – All current methods are less than ideal
• Governmental Influences– Subsidies – Regulation
• Energy Market Fluctuations• Competing Technologies• Implications of GMO algal species
What is the optimal PBR Design Balance?
Answer: It depends
• Regional and site specific• Variable input characteristics• Must be ready to adjust and make trade offs to
achieve the most profitable system possible.
Questions?
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