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ALGAE TO ETHANOL: Using algae fermentation to produce ethanol

ALGAE TO ETHANOL: Using algae fermentation to produce ethanol . 4 th AFRICAN BIOFUEL CONFERENCE March 2009. Algae!. Why Algae?. Fast growers relative to other plants and animals can double their weight every day High carbohydrate/low lignin content Gallons of oil per acre per year

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ALGAE TO ETHANOL: Using algae fermentation to produce ethanol

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  1. ALGAE TO ETHANOL: Using algae fermentation to produce ethanol 4th AFRICAN BIOFUEL CONFERENCE March 2009

  2. Algae!

  3. Why Algae? • Fast growers relative to other plants and animals • can double their weight every day • High carbohydrate/low lignin content • Gallons of oil per acre per year • corn 18 • soybeans 48 • sunflower 102 • rapeseed 127 • oil palm 635 • micro algae 5 000 - 15 000

  4. Process Selection Objectives… • Must be simple • The process itself must be “bullet proof” • Must have low maintenance • A labourer must be able to look after algae production • A semi-skilled labourer must be able to run conversion • Must have low operating costs • little or no nutrient cost • little or no energy cost

  5. Why ethanol and not oil for biodiesel?

  6. Why Algae to Ethanol… • Wild algae • have to be fast growers to survive in nature • generally contain <10% oil (lipid) • generally contain high carbohydrate >50% • can be grown in open raceways without fear of contamination • Equipment • raceways are low cost installations ($75 000/ha) • raceways consume very little power (10 kW/ha) • starch to ethanol conversion plant is relatively expensive and energy intensive (distillation)

  7. Why Algae to Ethanol… • High oil producing algae • are slower growers than wild algae – double every 2-3 days • can be selected for maximum oil content – 50% not unusual • need to be grown in protected environment – typically PBR’s • most algae oil can be used for biodiesel production • Photobioreactors (PBR’s) • allow tight control of growing environment • optimise light usage • are capital intensive • are generally power intensive (300 kW/ha?)

  8. General Processing Steps Algae to Ethanol

  9. Processing Steps CO2 sunlight oxygen Algae

  10. Processing Steps CO2 sunlight oxygen Algae dlute slurry liquid Concentration

  11. Processing Steps CO2 sunlight oxygen Algae dlute slurry liquid Concentration concentratedslurry acid Hydrolysis heat

  12. Processing Steps CO2 sunlight oxygen Algae dlute slurry liquid Concentration concentrated slurry acid alkali Hydrolysis Fermentation heat cooling yeast

  13. Processing Steps CO2 sunlight oxygen Algae dlute slurry liquid ethanol Distillation Concentration concentrated slurry “beer” acid alkali Hydrolysis Fermentation heat cooling yeast

  14. Processing Steps CO2 sunlight oxygen Algae Digestion dlute slurry liquid stillage ethanol Distillation Concentration concentrated slurry “beer” acid alkali Hydrolysis Fermentation heat cooling yeast

  15. Processing Steps CO2 sunlight oxygen biogas solid digestate liquid digestate Algae Digestion dlute slurry liquid stillage ethanol Distillation Concentration concentrated slurry “beer” acid alkali Hydrolysis Fermentation heat cooling yeast

  16. Processing Steps CO2 sunlight oxygen biogas solid digestate liquid digestate Algae Digestion dlute slurry liquid stillage ethanol Distillation Concentration CO2 concentrated slurry “beer” acid alkali Hydrolysis Fermentation heat cooling yeast

  17. Processing Steps CO2 sunlight oxygen biogas solid digestate liquid digestate Algae Digestion dlute slurry liquid stillage ethanol CO2 Distillation Concentration CO2 concentrated slurry “beer” acid alkali CO2 Hydrolysis Fermentation heat cooling yeast

  18. Processing Steps ~ CO2 CHP CO2 sunlight oxygen biogas solid digestate liquid digestate Algae Digestion dlute slurry liquid stillage ethanol CO2 Distillation Concentration CO2 concentrated slurry “beer” acid alkali CO2 Hydrolysis Fermentation heat cooling yeast

  19. Pilot Plant

  20. Pilot Plant • Components • 20m2 raceway with 0.55 kW paddle drive • solar panels to supply heat to the digester

  21. Pilot Plant

  22. PilotPlant

  23. Pilot Plant

  24. Pilot Plant • Components • 20m2 raceway with 0.55 kW paddle drive • solar panels to supply heat to the digester • digester

  25. Pilot Plant

  26. Pilot Plant • Components • 20m2 raceway with 0.55 kW paddle drive • solar panels to supply heat to the digester • digester • “compost tea” maker

  27. Pilot Plant

  28. Pilot Plant • Components • 20m2 raceway with 0.55 kW paddle drive • solar panels to supply heat to the digester • digester • “compost tea” maker • DAF container to make “white water”

  29. Pilot Plant

  30. Pilot Plant

  31. Pilot Plant

  32. Pilot Plant • Components • 20m2 raceway with 0.55 kW paddle drive • solar panels to supply heat to the digester • digester • “compost tea” maker • DAF container to make “white water” • stainless steel pressure cooker

  33. Pilot Plant

  34. Pilot Plant • Components • 20m2 raceway with 0.55 kW paddle drive • solar panels to supply heat to the digester • digester • “compost tea” maker • DAF container to make “white water” • stainless steel pressure cooker • plastic fermenter

  35. Pilot Plant

  36. Pilot Plant • Components • 20m2 raceway with 0.55 kW paddle drive • solar panels to supply heat to the digester • digester • “compost tea” maker • DAF container to make “white water” • stainless steel pressure cooker • plastic fermenter • electrically operated stainless steel batch still

  37. Pilot Plant

  38. Pilot Plant • Components • 20m2 raceway with 0.55 kW paddle drive • solar panels to supply heat to the digester • digester • “compost tea” maker • DAF container to make “white water” • stainless steel pressure cooker • plastic fermenter • electrically operated stainless steel batch still • various tanks, pumps, drums and buckets

  39. Pilot Plant

  40. Pilot Plant Results • Main Production Results • algae density 4 gram/litre • growth 140 g/m2/day • oil recovery negligible • ethanol production 50 - 70 ml ethanol/m2/day

  41. Moving Toward Commercialisation

  42. Production Plant Projection

  43. Production Plant Projection

  44. Commercial Production • Physical requirements • relatively level site

  45. Commercial Size Site

  46. Commercial Size Site

  47. Commercial Size Site

  48. Commercial Production • Physical requirements • relatively level site • water • power to drive paddles • Potential deployment for “emerging farmers” • can be deployed to tribal areas • relatively low cost for ponds ~ R75/m2 • centralized conversion plant: • can use a tanker for moving algae nutrient and concentrate to and from algae ponds to centralized plant • better economy of scale for larger plant • better process and inventory control

  49. Challenges to Commercialization • Oil price stability • High capital cost • Limited markets at small volumes • Theft of product • Challenges to tribal area deployment • Power for paddles: solar? • Theft and vandalism – cables, tanks and pumps are vulnerable

  50. Summary • Production of algae to produce ethanol is economically viable • Wild algae production does not require a lot of attention • Can be rolled out for emerging farmers • Conversion plant operation requires semi-skilled expertise

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