Algae Photobioreactor Design
Considerations for Commercial
Scale Production
Presented by:
Greg Karr
Serving Clients One Breakthrough at a Time
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
MRI Florida raceway open pond
• Lower production rates, yields and product value
• Production rates and product values do not offset
costs (under normal conditions)
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) MRI KC AlgaeLink PBR, 3500 L
•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?
Capital Costs
Unit basis ($ cost/$ revenue)
Higher
Lower
Investment Risk
Land Usage
Light Collection
Service Life
Production Controls
Productivity
Product Value (species selection)
Operational Costs
Unit basis ($ cost/$ revenue)
Higher
Lower
Labor
Maintenance
Utilities
Water source
Growth Nutrients
Gas input (source and energy)
Culture Maintenance
Revenues
Adding Value
Lower Value
Biomass Combustion
Animal Feed
Algal Oil
Liquid Biofuel Feedstocks (starches/celluloses)
High Value Compounds
Waste reduction (water/fertilizers)
CO2 mitigation
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?