CA2761251A1 - Fast erectable bioreactor - Google Patents
Fast erectable bioreactor Download PDFInfo
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- CA2761251A1 CA2761251A1 CA2761251A CA2761251A CA2761251A1 CA 2761251 A1 CA2761251 A1 CA 2761251A1 CA 2761251 A CA2761251 A CA 2761251A CA 2761251 A CA2761251 A CA 2761251A CA 2761251 A1 CA2761251 A1 CA 2761251A1
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- bioreactor
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
- C12M21/00—Bioreactors or fermenters specially adapted for specific uses
- C12M21/02—Photobioreactors
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
- C12M23/00—Constructional details, e.g. recesses, hinges
- C12M23/02—Form or structure of the vessel
- C12M23/04—Flat or tray type, drawers
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
- C12M23/00—Constructional details, e.g. recesses, hinges
- C12M23/02—Form or structure of the vessel
- C12M23/18—Open ponds; Greenhouse type or underground installations
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
- C12M23/00—Constructional details, e.g. recesses, hinges
- C12M23/22—Transparent or translucent parts
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
- C12M23/00—Constructional details, e.g. recesses, hinges
- C12M23/26—Constructional details, e.g. recesses, hinges flexible
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
- C12M23/00—Constructional details, e.g. recesses, hinges
- C12M23/38—Caps; Covers; Plugs; Pouring means
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
- C12M23/00—Constructional details, e.g. recesses, hinges
- C12M23/48—Holding appliances; Racks; Supports
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- Life Sciences & Earth Sciences (AREA)
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Abstract
A low-cost, durable, receptacle for microalgae farming such as a hybrid raceway-type pond/photobioreactor made from a rollable transparent/tamslucent flat sheet of semi-rigid plastic such as fiberglass which borders, when raised and engaged inside a repeating pattern of shape-sustaining c-shape braces, become rigid. The bioreactor may be erected on land or on sea without tools or fasteners and may include a water jacket, a solar reflector, an artificial LED lighting system and an agitator. The braces of the invention may also rigidize other receptacles such as floatable vessels, pipes, canals, tanks, troughs, solar sills, desalination tanks and gutters.
Description
FAST ERECTABLE BIOREACTOR
BACKGROUND OF THE INVENTION
Field of the Invention This invention relates to an apparatus for the production of biomass and more particularly to cultivating biomass in a fast erectable closable bioreactor.
More specifically, this invention also relates to roll of flat sheet that converts without requiring tools or fasteners into a receptacle such as, but not limited to, an elongate raceway-type pond, a photobioreactor, a canal, a pipe, a trough, a floatable vessel, a tank, a solar sill, a desalination tank and a gutter.
Description of the related art Recent international events have spurred interest in alternative energy sources, placing great emphasis on algal biofuels, although commercial algae farming is also important to nutriceutical, pharmaceutical, and aquaculture industries.
Among the greatest roadblocks to commercial scale algal production is the method of mass culture. The vast number of different bioreactor concepts is testimony that the best algal farming methods are still to be found. Most bioreactor designs are not suitable for commercial use due to cost and scale-up problems.
In contrast to bioreactors, pond technologies are commercially viable today, but have well-established problems of their own. Hybrid technologies might provide the control offered through closed bioreactors and the scalability afforded by open ponds.
To appreciate the value of attempts made and associated prior art, a short review of recent studies and related publications has revealed the following:
According to Mario R. Tredici: "Outdoors, under full sunlight, the photosynthetic efficiency drops to one tenth-one fifth of the values observed at low irradiances. The major causes for this inefficiency are the light saturation effect (LSE) and photoinhibition, phenomena that strongly limit the growth of microalgae in outdoor culture, although these because of the high cell density, are light-limited. The main problem is that photosynthetic apparatus of phototrophs saturates at low irradiances (typically from 1/20 to 1/10, 100 and 300 of full sunlight) and that, at irradiances above saturation, the absorbed photons are used inefficiently and may cause cell injury. Several strategies to overcome the LSE and photoinhibition have been proposed, based on engineering (light dilution, ultra high cell density culture, high turbulence), physiologic (photoacclimation, nutrient deprivation) or genetic.
. . ." (Tredici M. R.
(2004) Mass production of microalgae: photobioreactors. In Richmond A (ed.), Handbook of Microalgae Culture. Blackwell Publishing, Oxford (UK), pp 178-214.
Dimanshteyn taught in US Pat. 7,824,904 that photobioreactors generally consist of a container containing a liquid medium that is exposed to a light source.
However, the configuration of the photobioreactor often prevents the light from penetrating more than a few centimeters from the surface of the liquid. This problem reduces the efficiency of the photobioreactor, and was recognized in "Solar Lightning for Growth of Algae in a Photobioreactor" published by the Oak Ridge National Lab and Ohio University:
Light delivery and distribution is the principle obstacle to using commercial-scale photobioreactors for algae production. In horizontal cultivator systems, light penetrates the suspension only to 5 cm leaving most of the algae in darkness. The top layer of algae requires only about 1/10, 100 and 300th the intensity of full sunlight to maximize growth, so the remaining sunlight is wasted.
As described in Healthy Algae, Fraunhofer Magazine, January 2002, "Algae are a very undemanding life form--they only need water, CO2, nutrients and sunlight.
However, providing sufficient sunlight can be a problem in large scale facilities. "As the algae at the surface absorb the light, it does not penetrate to a depth of more than a few millimeters. The organism inside the unit gets no light and cannot grow," explains Walter Troesch, who has been cultivating algae for years. "This is the reason why there are only a few Algae production units dotted around the world. One of the problems with growing algae in any kind of pond is that only in the top 1/4" or so of the pond receives sufficient solar radiation for the algae to grow. In effect, this means that the ability of a pond to grow algae is limited by its surface area, not by its volume."
In summary, "the ability of a pond to grow algae is limited by its surface area, not by its volume." Therefore limitation in prior art will be examined in consideration of the above findings.
Traditional procedures employed for culturing autotrophic organisms have involved the use of shallow open ponds or open channels exposed to sunlight. Not surprisingly this comparatively crude method has proved impracticable for production of pure high grade products because of such problems as invasion by hostile species (sometimes producing dangerous toxins), other pollution (such as dust), difficulty in the control of such variables as nutrient ratios, temperature and pH, intrinsically low yield because of escape of carbon dioxide to the atmosphere and inefficient use of light to illuminate only the top portion of the biomass.
Somewhat more sophisticated attempts have involved the use of horizontally disposed large diameter transparent plastics tubes for biomass production. The problems of such a system include the low density of biomass in the liquid within the tubes, coating of the pipes by algae due to low velocity flow therethrough thus reducing transparency, overheating in summer weather, high land usage and high energy input to displace large amount of un-necessary diluted water.
Now, looking more closely at receptacles that could have been potentially used as closed systems for creating a low-cost raceway-type pond or a photo bioreactor, a number of prior art are examined.
U.S. Pat. No. 7,069,875 to Warecki ("Warecki") discloses a large and low cost portable raceway or vessel for holding flowable materials. The vessel has a body formed of an elongate rollable sheet of buoyant material that when assembled into an upwardly concave vessel has bulkheads at its ends to give it its half rounded shape. The large vessel is self-supporting in both water and land. The Warecki vessel suffers from a number of limitations.
Joining of parts such as bulkheads to the body of the vessel requires welding, chemical bonding, and/or mechanical fastening. Also, to maintain the shape of the pond, bulkhead bow frames must be positioned inside the vessel, dividing the space into closed compartments that are fastened mechanically or chemically to the body, although some unsecured movable compartments are used.
World Patent No.W02011016735 to Dalrymple discloses an erectable trough for animal feed.
The plastic sheet disclosed by Darlymple is bent into a U-shaped trough with opposite side walls being supported upright by tension wires through perforations in the side walls. As disclosed, the trough is not waterproof and not suitable for a raceway.
U.S. Pat. No. 5,846,816 to Forth ("Forth") discloses a biomass production apparatus includes a transparent chamber which has an inverted, triangular cross-section.
Although the Forth bioreactor promotes the growth of biological matter, it contradicts the principles extensively tested by Tredici, Fraunhofer and National Labs that assert the need to maximize exposed surface area relative to the volume displaced. Furthermore, the disclosed chamber is expensive to manufacture. Finally, the constant circulation of the liquid required by Forth interfers with the growth of some types of biological matter. For instance, fully differentiated aquatic plants from the lemnaceae or "duckweed" family are fresh-water plants that grow best on the surface of the water. Such surface growing plants typically prefer relatively still water to support and promote optimal growth.
To overcome limitations of prior art, the present invention seeks to provide an improved raceway-type pond with features of a photo bioreactor system that maximize the surface area exposed to sunlight in relation to the volume of algal solution; additionally, the invention seeks to provide a closable pond that promotes the growth of plant biological materials in a relatively sterile environment isolated from contaminants.
Furthermore, to reduce land usage, the present invention teaches an improved transparent/translucent hybrid raceway-type pond/photo bioreactor positionable in an elevated structure to maximize exposure to sunlight from all directions including from the underside which receives additional light from a solar reflector system.
Additionally, to overcome the high costs associated with most bioreactor designs and their short life expectancy, a worldwide problem that is impairing the commercial scale-up of the technology, the invention discloses a cost-effective transparent/translucent material such as, but not limited to, a durable, elongate, rollable flat sheet of semi-rigid fiber reinforced plastics (FRP) that may be re-shaped to become a hard thin-shell body to withstand stresses put on the elevated and suspended pond. It is known that FRP has a life expectancy beyond 10 to 25 years and that it can be produced in conventional production facilities cost-effectively.
Furthermore, to further reduce costs of production, transport, storage, distribution, handling and installation, the FRP sheets of the invention are configured to be thin enough to be rollable but rigid enough to withstand tough weather conditions and bending stresses. The rollability of thin FRP enables its borders to be bent so that they can engage into a repeating pattern of shape sustaining self-locking braces that maintains the shape of the pond.
Finally, by inserting, incorporating or attaching a number of thin sensors, detectors, wires, LED tapes, closable portholes, reflector films and other related equipment to laminar films that are incorporated to the FRP sheets during manufacturing, it is possible to further reduce costs of operation, control and monitoring of the system during operations.
And not the least, to overcome the generally high energy demand of prior art microalgae farming systems, the pond of the invention is provided with a low-energy demanding agitator and Light Emitting Diodes to provide artificial light during dark hours.
SUMMARY OF THE INVENTION
According to an embodiment, the invention is a repeating pattern of c-shape braces that have a generally flat portion flanked between two curved sidewalls each ending with a reverse bend. Engaging a flat sheet of semi-rigid material without tools or fasteners inside the shape-sustaining braces converts the flat sheet into an elongate receptacle-like thin-shell body such as a pond able to withstand higher bending stresses than typical.
According to another embodiment, the invention is a fast erectable closable transparent/translucent raceway-type pond having some features of a photo bioreactor system. The pond is comprising a transparent/translucent semi-rigid rollable sheet which shape is sustained by a repeating pattern of braces that imparted their shape to the pond.
Besides the general form of the braces, two other factors determine the size and shape of the braces: the length of the braces is substantially similar than the width of the semi-rigid sheet and the ends of the braces are provided with a reverse bend. These reverse bends create a self-locking effect that secure tightly the sheet edges into the braces.
It is known that raising borders of a semi-rigid sheet and maintaining such a shape throughout the length of the sheet stiffens that sheet. In this invention, the combination sheet, braces of the invention and their reverse bends creates a thin-shell structure able to convert bending stresses into tension and compression stresses enabling the structure to act more like a pre-tensioned beam rather than a plate. Consequently, disclosing a stronger pond that requires less material and less support than typical structures provides a more cost-effective solution for commercial scale-up of biomass production.
In a further embodiment of the invention, the combination sheet and braces enables to rapidly erect a pond from a substantially compact condition such as a roll, into a fully expanded condition such as an elongate pond. Such a feature reduces costs of storage, transport and time for installation. Furthermore, providing a pond that is translucent or transparent/translucent enables the pond to receive sunlight from all directions, thus increasing photon intake. To further reduce land usage, the pond may be suspended to or supported by load-carrying structures such as arc-shape, gothic-shape, reverse u-shape, A-shape or T-shape structures or to greenhouse and warehouse frames and structures of the like.
In an embodiment of the invention, the length of braces sidewalls is kept short on both sides.
Consequently, the sheet engaged in the repeating pattern of such braces defines an open pond. To close the pond, a removable, sealable and rollable cover is provided.
The cover may include components such as, but not limited to, connectors, sensors, detectors and portholes for oxygen removal.
In another embodiment of the invention, braces sidewalls extend to meet over the middle portion of the pond. Therefore, the sheet engaged in these braces takes the shape of a pond having two semi-covers closable at mid-point of the pond by a sealable profile.
In yet another embodiment of the invention, one of the braces sidewalls extends and overlaps the other side shorter sidewall. In this arrangement, the overlapping sheet engaged in those braces is also closable by a sealable profile.
According to another embodiment, the pond is floating over water and is supported by floats and buoys and by inflatable buoyancy units that may lower or elevate the pond, making exit of an aqueous solution and media contained in the pond more effective.
Alternately, the pond floats over water without requiring support from floats or buoys.
Preferably, all ponds of the invention are agitated by either a paddle wheel, a pump that circulates water or a wave generator that rotates an axle provided with a mechanism that generates a reciprocating up and down motion. The wave generator comprises a repeating pattern of eccentric cams that move up and down a pond support means, such as a cable or a chain, that supports one side or both sides of the pond.
In all embodiments of the invention, the sheet borders or the sealable profile that cooperates with said borders may include Light Emitting Diodes, sensors and detectors.
According to another embodiment, the pond of the invention includes a dewatering system defined by a sleeve filled with an aqueous solution and media for biomass growth. The sleeve is made of a transparent plastic film on the upper side and of an osmosis membrane on the lower side. In this embodiment, the sleeve is floating over a salty water of higher concentration than the aqueous solution in the sleeve. Dewatering takes place when the water content in the sleeve permeates into the salty water. Later, the biomass paste remaining inside the sleeve after dewatering is extracted by squeezing the sleeve and its content with rollers.
Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a roll being erected into a receptacle.
FIG. 2 is a perspective view of an open bioreactor with a cover.
FIG. 3 is a perspective view of a sheet curved to incorporate its own cover.
FIG. 4 is a perspective view of a sheet curved with one side overlapping the other.
FIG. 5 is a cross-sectional view of a detail of FIG. 4 FIG. 6 is a perspective view of multiple bioreactors supported by an A-shape structure.
FIG. 7 is a perspective view of a floatable bioreactor including a sleeve inside. FIG. 8 is a perspective view of two ponds supported by an arc-shape structure.
FIG. 9 is a front view of a double-wall pond with a water jacket supported by a U-structure.
FIG. 10 is a side view of a sleeve incorporating a flexible sparger.
DETAILED DESCRIPTION OF THE INVENTION
It will be appreciated that the present invention may be used to produce biomass of various types and forms or products derived from the biomass. The term "biomass" as used herein includes all organisms capable of photosynthetic growth such as plant cells and microorganisms (including algae and euglena) in unicellular or multicellular form that are capable of growth in a liquid phase. The term may also include organisms modified artificially or by gene manipulation.
The terms "receptacle", "bioreactor" and "pond" are used interchangeably in this invention to refer to any waterproof enclosure, container, chamber, vessel, canal, pipe, trough, tank, solar sill, desalination tank, gutter and other U-shape containers that are shaped by the braces of the invention able to contain a flowable material including organisms capable of photosynthetic growth. And more particularly, the term bioreactor refers to raceway-type ponds and photobioreactors also known as AlgaReactorTm (is a Trade Mark and a URL
Domain name of S. Mottahedeh).
The present invention discloses a fast erectable closable pond having features of a photo bio-reactor (PBR) that use light to grow a photosynthetic biomass such as a microalgae.
According to some embodiments of the invention, the fast erectable pond is made of a durable, resistant and long lasting semi-rigid thin material such as, but not limited to, Fiber Reinforced Plastic (FRP) that take on both a compact condition such as being reduced to a roll and an expanded or erected condition such as taking the shape of an elongate pond.
In the preferred embodiment of the invention, a semi-rigid sheet is rigidized by raising and curving said sheet borders and by engaging them inside a repeating pattern of c-shape braces sized with an interior perimeter substantially similar to the width of the sheet. The word 'c-shape' is used here to mean any kind of geometrical shape, including but not limited to square, rectangular, elliptical or curved in any other way, and the word `c-shape brace' will be referred to as 'brace' to express the same meaning.
Braces of the invention are configured with a generally flat base portion flanked between two curved sidewalls each ending with a reverse bend. By girding and bracing a semi-rigid sheet inside a brace and then by locking the movement of the sheet by a reverse bend system enables to transfer bending stresses exposed to the sheet into compression and tension stresses that are generally well withstood particularly by glass fibers and the polyester resins present in FRP sheets. Consequently, the combination sheet and braces of the invention defines a pond that requires less support than other pond structures therefore providing a more cost-effective solution for commercial scale-up of biomass production from microalgae.
Preferably, braces are located at equal distance in a repeating pattern to sustain the shape of the pond along the pond.
In a preferred embodiment of the invention, the fast erectable pond is configured with braces having sidewalls ending short on both sides. Consequently, the sheet engaged in such braces defines an open pond. To close such a pond, a removable, sealable and preferably rollable cover is provided. The cover may include components such as, but not limited to, connectors, sensors, detectors and portholes for oxygen removal. The cover, also made of a rollable semi-rigid material includes closable apertures. To ensure a tight closure during high winds, a strap is further provided to wrap around the cover and the pond.
In another embodiment of the invention, one of the braces sidewalls extends over the pond to overlap the opposite shorter sidewall. A semi-rigid sheet engaged in such braces defines a pond having its own integrated cover using a single sheet. Such a cover is liftable for providing access to the pond inner space.
In the above embodiment, one end of the combination sheet and braces is fastened to an elonagte sealable profile that engages sealingly with the other end of the same combination for enabling the opening and full closure of the pond. This elongate sealable profile includes cavities and bulges for holding equipment to enhance the growth of biomass.
Such equipment include, but not limited to, fastenable hangers that extend into said pond to support equipment, spargers, flexible wires, sensors, monitors, detectors, connectors, Light Emitting Diodes (LED) tapes or strips, computer chips, opto-electronic sensors, bluetooth (RF)-based short-range connectivity, photovoltaic cells, batteries, microplate readers and a combination thereof.
In another preferred embodiment of the invention, the pond includes a cooling or heating system comprising an arrangement of a second layer of a rollable semi-rigid transparent/translucent sheet of substantially same width that is inserted and engaged fittingly into the same braces of the invention over the first semi-rigid sheet already engaged fittingly inside the braces. The bottom portion of overlaid sheets is kept slightly apart by a transparent spacer positioned in between them. The spacer has cavities for circulating a fluid therein, thereby creating a water jacket.
Preferably, all semi-rigid rollable materials provided in the present invention are best made of materials selected from the group consisting of transparent/translucent or translucent materials selected from the group consisting of, Fiber Reinforced Plastic (FRP), Low Density Polyethylene (LDPE), High Density Polyethylene (HOPE), Rigid acrylic (PMMA), Poly vinyl chloride (PVC), composite plastics and of a combination thereof.
The word 'transparent' is used here to mean any degree of transparency, including but not limited to translucent materials and all materials transparent to visible light.
Preferably, braces are best made of materials selected from the group consisting of thin-gauge metal strips stiffened by ribs, of rigid fiberglass blanks, of wood laminates, of plastic composites, of cementitious material such as clay, ceramics, glass, of fiber cement and of a combination thereof.
To maximize exposure of a pond to solar radiation, the pond of the invention is made of a transparent/translucent material and is positioned in an elevated site relative to the ground or relative to a surface of water, so as to enhance maximum capture of photons from all directions including light that may be captivated from the pond underside.
To keep the pond in an elevated position, the pond braces are supported by a number of support means positioned either under the braces or on the side of braces. In one embodiment, braces are suspended on one side by chain or cable means and on the other side are secured by clamp means to fixed members. This arrangement enables, from one side, to modify the height of a pond to achieve a reasonable water level throughout the length of the pond, and from the other side, to agitate the pond with an up and down motion via a reciprocating mechanism, defined as a wave generator.
The support means mentioned above are cooperating securely with load-carrying structures selected from the group consisting of a reverse U-shape structure, an A-shape structure, a T-shape structure, a gothic-shape structure, an arc-shape structure, a greenhouse structure and a combination thereof.
To further increase photon capture by a pond, a reflective film or other reflective materials such as paint or reflective minerals are laid on the ground under the pond.
The solar light reflector of the invention is positioned slightly sideways under the pond to reflect solar light towards the pond underside. This solar light reflector comprises a reflective film suspended between two tension wires in a manner that the film adopts a substantially parabolic-shape curve that directs solar radiation to the underside of the pond.
For locations where the cost of land is expensive, or to reduce land usage in general, it is preferable to maximize the exposed surface relative to the pond footprint. To achieve this, a multi-level arrangement of staggered ponds is taught by this invention. In an example, multiple ponds may be supported by arc-shape or gothic support means such as supports provided in a greenhouse.
In an example of a modular load-carrying structure, a reverse u-shape structure carrying a single pond is also configured to cooperate like a scaffold with other reverse u-shape structures to collectively create a multi-stage pond system. The u-shape structure is comprising a repeating pattern of horizontal bars, each having ends secured to two vertical bars or pipes enabling the horizontal bar to be height adjustable via a clamp-type arrangement. In such a modular system, ponds are staggered to capture maximum amount of light during sunlight hours with minimum shade. The solar reflector of the invention is configured to reduce this shade by illuminating the underside of the ponds.
In another example, multiple ponds may be supported by an A-shape load-carrying structure comprising of two converging members that support a horizontal arm that hinges at a point located substantially between a short portion of said arm and a long portion;
the end of the arm long portion is supported by a vertical member securing an axle transmitting a reciprocating up and down motion to the horizontal arm.
By providing a counterweight positioned at the end of the horizontal arm short portion, some of the weight of the ponds may be offset. This minimizes the amount of energy needed by the horizontal arm to agitate the ponds and consequently by the reciprocating up and down mechanism and by the motor that drives it. By phasing out gradually, such as at 90 degree angle, the up and down movement of the horizontal arm along the transmission axle and along the connecting points of the repeating pattern of up and down mechanism, it is possible to reduce substantially the amount of energy needed to agitate the ponds. For example, for a 90 degree rotation of the axle, the first horizontal arm is pushed up, the second arm is pushed forward, the third is pushed down and the fourth arm is pushed backward.
Agitation of the aqueous solution with media may also be achieved by the traditional water wheel. In this invention, the horizontal axis of the water wheel is made to rest over the pond sidewalls with a casing configured to cooperate sealingly with the pond cover.
In another embodiment of the invention, a pond is supported over a span of water by floats or buoys and preferably by multiple inflatable buoyancy units able to lower and elevate the pond for easy exit from the pond of an aqueous solution and media contained in the pond. In this embodiment, the pond is kept slightly elevated from a surface of water such as the sea, said water surface being also covered by a floating reflector such as a bubble-film reflector. This arrangement provides multiple advantages. The natural movement of waves in a sea provides the desired agitation required to grow microalgae. Placing a light reflecting film floating underneath a pond reduces substantially the amount of "blackness" and "light absorption"
effect of the sea. Also, the bubble-film reflector enhances solar light reflection. Both of said effects increase photon capture by the pond. Also, as land usage is becoming more expensive with increasing population, using more ocean surfaces is becoming more prevalent. Additionally, the cooling effect of surrounding ocean water keeps temperature of the pond stable.
And finally, salt water being of higher concentration than sweet water such as from a water treatment plant, may be used to dewater a continuous flow or a batch-by-batch volume of an aqueous solution containing media for biomass production. In the present invention, seawater is introduced into the pond and the sleeve is made to float inside the pond over said seawater. By providing the sleeve with an osmosis membrane, the semi-liquid media containing biomass in the sleeve is gradually dewatered.
To best enhance biomass growth, multiple smaller length of sleeve portions like elongate bags containing batches of aqueous solution with media are attached together and are made to follow each other, similar to long detachable sausages that are gradually floated to mature over the pond on fresh water or salty water. The elongate bags are slowly moved forward, collectively or one by one, until the biomass reaches a mature stage where they are individually detached, retrieved from the pond and squeezed to extract the biomass paste from which oil will be extracted.
NASA developed a similar osmosis process called the OMEGA project. The difference between the OMEGA project and the pond system of the invention is that dewatering in the OMEGA project takes place with the sleeve fully immersed or in direct contact with the ocean, whereas in the present invention, the sleeve remains constantly in the pond that may be located anywhere on land. In the present invention, all parameters enhancing the growth of the biomass may be controlled, on land, during the biomass growth and the dewatering process. Additionally, a pond system such as raceway-type pond may be extended first in a direction away from the shore and then back towards the shore enabling to maintain full control of the entire process on firm land base. Furthermore, providing the pond with spargers, artificial light from Light Emitting Diodes (LED) during dark hours, sensors and detectors increases substantially biomass production level.
In yet another embodiment of the invention, the pond further includes a combination of a sterilized disposable transparent plastic sleeve with an integral disposable sparger in it. In this embodiment of the invention, growing biomass in such a disposable sterilized combination sleeve and disposable sparger positioned inside the pond obsoletes the need to clean the pond, provides a sterilized environment for growing sensitive microalgae species, shields the pond content against contamination from outside elements and enables quick access to the biomass by squeezing the sleeve by roller means to extract its content. It is known that sterilization of plastic bags is readily achieved by gamma rays.
In a further embodiment of the invention, the pond including an aqueous solution with media incorporates a dewatering system. The dewatering system consists of a half empty tube made of an osmosis membrane that contains salt water. Positioning said osmotic tube in the pond, absorbs by osmosis the sweet water from the biomass, causing it to dewater. The osmotic tube may be made large enough to line up the entire bottom part of a portion of the pond, so that the aqueous solution with media my rest on it.
In other embodiments, to supplement solar radiation during dark hours, the pond further includes artificial light by means of Light Emitting Diodes (LED).
Referring now to the figures and in particular to FIG. 1, a pond 10 best made of a semi-rigid material 12 is compacted into a roll 22 for easy storage, transport and installation in a first condition and is readily expanded into an erect condition such as to create a pond 10. Braces 1010 give to the pond its shape.
Referring now to FIG. 2, a preferred embodiment of an open pond is shown wherein pond 10 is comprising a semi-rigid sheet 12 shaped by a repeating pattern of shape-sustaining braces 110 that have a generally flat base portion flanked between two curved sidewalls each ending with a reverse bend 112 and 114. Pond 10 is provided with a cover 50 best made also of a rollable semi-rigid material. Cover 50 is provided with portholes 52 configured to connect to tubes for oxygen removal or for other purposes such as, but not limited to, looking into the pond 12 through lenses, hanging instruments, inputting nutrients, extracting samples or other usage. Naturally, these holes are not open directly to open air which may contaminate the pond 12 content but have air seals. Hangers 30 may attach to the sheet 12 sidewalls.
Hangers 30 may hold equipment such as a sparger 32 or sensors and detectors such as for pH or temperature control (not shown). Borders of sheet 12 are provided with a sealing means 60 such as a tape to seal the cover 50. A strap (not shown) is used to secure cover 50 and lean against sidewalls of pond 12 to withstand all weather conditions.
FIG. 3 refers to another embodiment of the invention wherein pond 10 is comprising of a semi-rigid sheet 12 shaped by a repeating pattern of braces 110 which sidewalls end 112 and 114 meet almost end-to-end at a central location. A sealing profile 70 secures sealingly the two semi-cover portions against any leakage or environmental contamination.
Pond 10 is supported on one side by clamps 116 and on the other side by suspension means 60. Clamps 116 are slidable over members of support means 80, such as member 82 from an A-frame (see FIG. 6).
Now referring to FIGS. 4, 5 and 7, yet another embodiment of pond 10 is shaped by a repeating pattern of braces 110 configured for braces end 112 to overlap braces other end 114. In this arrangement, pond 10 is provided with its own integral cover 50 created by extending one side of sheet 12 to cover and overlap the other side of sheet 10. Cover 50 is liftable on one side providing access to the pond content. An elongate sealing profile 70 is configured to secure, seal and lock together overlapping borders of sheet 12.
FIG. 5 shows more closely the cross-sectional profile of sealing profile 70 in the bubble A-A. Sealing profile 70 incorporates cavities and bulges 72 for securing equipment that enhance biomass growth in pond 10 such as tapes or strips of Light Emitting Diodes (LED) (40), fastenable hangers (30), spargers (30), flexible wires, sensors, monitors, detectors, connectors, (LED), computer chips, opto-electronic sensors, bluetooth (RF)-based short-range connectivity, transparent or opaque photovoltaic cells, batteries, microplate readers and a combination thereof.
In all embodiments of the invention, any or all equipment inserted, attached or incorporated in laminar form or in other forms to the semi-rigid sheets 12 and 50 of the invention during manufacturing or for other reasons may remain, preferably or if necessary, integrally attached to the sheet 12 when the sheet 12 is rolled for transport or storage reasons.
As mentioned earlier, some equipment such as reflective films, tapes incorporating sensors and detectors, LED tapes, wires 40, transparent or opaque photovoltaic cells or laminates of the like may be integrally built into the semi-rigid sheet 12 during the manufacturing process.
This integration is easily achievable for Fiber Reinforced Plastics (FRP) sheets 12 that already use laminated sheets as part of their manufacturing process. In an example, bands of reflective material 120 or of sensors (not shown) may be integrated at strategic locations into the FRP sheets 12 during manufacturing.
Now, as shown in FIGS. 6 and 8, multiple ponds 10 may be supported by load-carrying supports such as presented in pond system 1000 which is composed of a repeating pattern of individual support structures 80, each being configured to secure a repeating pattern of braces 110 that provide collectively a shape-sustaining support to each of the semi-rigid sheet 12 that define ponds 10.
Now referring particularly to FIG. 6, the pond system 1000 is composed of a repeating pattern of load-carrying A-shape structures, each comprising two converging members 82 and 84 that collectively support a horizontal arm 86-88 that hinges at a pivotal point located between a short portion 88 of the arm and a long portion 86, with the arm long portion 86 end being supported by a vertical member 81 that cooperates with an axle 210 that transmits a reciprocating up and down motion to the horizontal arm 86-88. Axle 210 is rotated by a drive means 220 which rotation speed is adjustable. To reduce the amount of energy required to drive motor 220 that moves the reciprocating mechanism 200, a counterweight 90 is suspended at the end of horizontal arm short portion 88.
Clustering ponds 10 together increases the total solar exposure of the biomass-producing area relative to the area of the pond footprint and reduces overall structural support costs. As shown in FIG. 6, ponds 10 are positioned in elevated locations and are staggered along an oblique line such as on member 82 to reduce shadow from other ponds 10. To reduce the shadow effect, a reflector 120 is positioned to reflect a more even distribution of solar radiation to the underside of ponds 10.
Other forms, sizes and shapes of load-carrying structures may be used. Such structures may include, but are not limited to, U-shape structures, T-shape structures, gothic-shape structures, greenhouse structures, warehouse structures or a combination thereof.
In an example of a modular load-carrying structure 80 as shown in FIG. 9, a reverse u-shape structure 80 carries a single pond 12 and is configured to cooperate like a scaffold system with similar reverse U-shape structures forming collectively create multi-stage pond systems 1000. The modular U-shape structure 80 is comprising a repeating pattern of height adjustable horizontal bars 81, each having ends secured to two vertical bars or pipes 83 and 85 secured to the horizontal bar 81 by a bolt via a clamp-type arrangement. In such a modular system 80, ponds are staggered to capture maximum amount of photons during sunlight hours with minimum shading affecting each other. The solar reflector of the invention 120 (not shown in this figure) is configured to reduce shade by illuminating the underside of the ponds 10.
Referring to FIG. 7, the lower film in sleeve 20 may be made of an osmotic membrane 320 configured to float over a span of salty water 16 covering partially pond 10.
As mentioned before, through the osmosis process, sweet water 18 contained in the aqueous solution permeates through the osmotic membrane 320 seeking to join the higher concentrated salt water 16 and in the process dewatering of the biomass grown in sleeve 20 takes place.
Alternately, instead of having sea water outside sleeve 20, sea water may be contained in an osmotic sleeve (not shown) made entirely of an osmotic membrane 320. Such an osmotic sleeve may be laid in direct contact with the aqueous solution 18 and media to dewater it.
In still another embodiment of the invention shown in FIG. 7, a floating pond 10 has braces 110 secured to floats, buoys or to buoyancy units 400. Some of buoyancy units 400 are inflatable so as to elevate or lower the pond 10 to enhance easy extraction of an aqueous solution and media contained in pond 10.
FIG. 8 refers to a repeating pattern of arc-shape load-carrying structure 80 that collectively support a pond system 1000 composed of two ponds 10 adjacent to each other and configured to counter-balance other each weight. Aqueous and biomass load carried by adjacent braces 110 associated to said adjacent ponds 10 may be counter-balanced by positioning said braces 110 on a pivoting arm (not shown) moved by axle 210 or by suspending one side of each of said adjacent braces 110 to a suspension means 60. The suspension 60 may in turn be moved by a reciprocating mechanism 200 that is rotated by axle 210. Similar to other embodiments of the invention, agitation of multiple ponds 10 may be achieved by securing one side of each pond 10 to clamp means 116, and by supporting, suspending or connecting the other side of pond 10 to the reciprocating mechanism 200.
Clamps 116 are affixed to braces 110 either hingingly, directly by welding or by rivet means or via tie means. Clamps 116 enable to achieve height adjustment of braces 110 and therefore of water level of ponds 10 along the full length of one side of a pond 10. A
similar adjustment of height is achievable by adjusting the length of suspension means 60 on the other side of braces 110.
FIG. 9 refers to another preferred embodiment of the invention wherein pond 10 includes a cooling or heating system comprising of a second layer of a rollable semi-rigid transparent/translucent sheet 22 laid over the first semi-rigid sheet 12 engaged already fittingly inside the same repeating patterns of braces 110. Said second sheet 22 has substantially the same width than the first sheet 12 and is also engaged fittingly into the same braces 110 of the invention at same locations. The lower portions of the two layers of sheets 12 and 22 are kept slightly apart by a transparent spacer 24 positioned in between the first sheet12 and the second sheet 22. The transparent spacer 24 has cavities for circulating a fluid 26 therein, thereby creating a water jacket.
A spacer 24 having cavities for circulating a fluid therein may include a thin multi-wall panel with space in between walls and enough wall thickness to withstand the load carried by pond exerted from the aqueous solution 18 with biomass. Wall shapes may include vertical-shape, zig-zag-shape, square-shape, wave-shape, 0-shape, cylindrical-shape, Z-shape and similar wall shapes of the like. Preferably, spacer 24 is also rollable for reducing transport and storage costs of pond 10.
Now FIG. 10 refers to a transparent sleeve 20 filled with an aqueous solution and media 18 for growing biomass. Sleeve 20 is comprising of a transparent film 310 cooperating sealingly with a flexible sparger 32, both being disposable and preferably made of biodegradable plastic. Flexible sparger 32 may be sealingly heat welded to plastic 310.
Alternately, instead of having sea water outside of sleeve 20, sea water may be contained in an osmotic sleeve (not shown) fully made of an osmotic membrane 320. The osmotic sleeve is brought in direct contact with the aqueous solution 18 and media to dewater it. The osmotic sleeve with sea water may come in direct contact with the aqueous solution and biomass inside of sleeve 20 or inside pond 10 without the presence of sleeve 20.
Certain features of this invention may sometimes be used to advantage without a corresponding use of the other features. While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
BACKGROUND OF THE INVENTION
Field of the Invention This invention relates to an apparatus for the production of biomass and more particularly to cultivating biomass in a fast erectable closable bioreactor.
More specifically, this invention also relates to roll of flat sheet that converts without requiring tools or fasteners into a receptacle such as, but not limited to, an elongate raceway-type pond, a photobioreactor, a canal, a pipe, a trough, a floatable vessel, a tank, a solar sill, a desalination tank and a gutter.
Description of the related art Recent international events have spurred interest in alternative energy sources, placing great emphasis on algal biofuels, although commercial algae farming is also important to nutriceutical, pharmaceutical, and aquaculture industries.
Among the greatest roadblocks to commercial scale algal production is the method of mass culture. The vast number of different bioreactor concepts is testimony that the best algal farming methods are still to be found. Most bioreactor designs are not suitable for commercial use due to cost and scale-up problems.
In contrast to bioreactors, pond technologies are commercially viable today, but have well-established problems of their own. Hybrid technologies might provide the control offered through closed bioreactors and the scalability afforded by open ponds.
To appreciate the value of attempts made and associated prior art, a short review of recent studies and related publications has revealed the following:
According to Mario R. Tredici: "Outdoors, under full sunlight, the photosynthetic efficiency drops to one tenth-one fifth of the values observed at low irradiances. The major causes for this inefficiency are the light saturation effect (LSE) and photoinhibition, phenomena that strongly limit the growth of microalgae in outdoor culture, although these because of the high cell density, are light-limited. The main problem is that photosynthetic apparatus of phototrophs saturates at low irradiances (typically from 1/20 to 1/10, 100 and 300 of full sunlight) and that, at irradiances above saturation, the absorbed photons are used inefficiently and may cause cell injury. Several strategies to overcome the LSE and photoinhibition have been proposed, based on engineering (light dilution, ultra high cell density culture, high turbulence), physiologic (photoacclimation, nutrient deprivation) or genetic.
. . ." (Tredici M. R.
(2004) Mass production of microalgae: photobioreactors. In Richmond A (ed.), Handbook of Microalgae Culture. Blackwell Publishing, Oxford (UK), pp 178-214.
Dimanshteyn taught in US Pat. 7,824,904 that photobioreactors generally consist of a container containing a liquid medium that is exposed to a light source.
However, the configuration of the photobioreactor often prevents the light from penetrating more than a few centimeters from the surface of the liquid. This problem reduces the efficiency of the photobioreactor, and was recognized in "Solar Lightning for Growth of Algae in a Photobioreactor" published by the Oak Ridge National Lab and Ohio University:
Light delivery and distribution is the principle obstacle to using commercial-scale photobioreactors for algae production. In horizontal cultivator systems, light penetrates the suspension only to 5 cm leaving most of the algae in darkness. The top layer of algae requires only about 1/10, 100 and 300th the intensity of full sunlight to maximize growth, so the remaining sunlight is wasted.
As described in Healthy Algae, Fraunhofer Magazine, January 2002, "Algae are a very undemanding life form--they only need water, CO2, nutrients and sunlight.
However, providing sufficient sunlight can be a problem in large scale facilities. "As the algae at the surface absorb the light, it does not penetrate to a depth of more than a few millimeters. The organism inside the unit gets no light and cannot grow," explains Walter Troesch, who has been cultivating algae for years. "This is the reason why there are only a few Algae production units dotted around the world. One of the problems with growing algae in any kind of pond is that only in the top 1/4" or so of the pond receives sufficient solar radiation for the algae to grow. In effect, this means that the ability of a pond to grow algae is limited by its surface area, not by its volume."
In summary, "the ability of a pond to grow algae is limited by its surface area, not by its volume." Therefore limitation in prior art will be examined in consideration of the above findings.
Traditional procedures employed for culturing autotrophic organisms have involved the use of shallow open ponds or open channels exposed to sunlight. Not surprisingly this comparatively crude method has proved impracticable for production of pure high grade products because of such problems as invasion by hostile species (sometimes producing dangerous toxins), other pollution (such as dust), difficulty in the control of such variables as nutrient ratios, temperature and pH, intrinsically low yield because of escape of carbon dioxide to the atmosphere and inefficient use of light to illuminate only the top portion of the biomass.
Somewhat more sophisticated attempts have involved the use of horizontally disposed large diameter transparent plastics tubes for biomass production. The problems of such a system include the low density of biomass in the liquid within the tubes, coating of the pipes by algae due to low velocity flow therethrough thus reducing transparency, overheating in summer weather, high land usage and high energy input to displace large amount of un-necessary diluted water.
Now, looking more closely at receptacles that could have been potentially used as closed systems for creating a low-cost raceway-type pond or a photo bioreactor, a number of prior art are examined.
U.S. Pat. No. 7,069,875 to Warecki ("Warecki") discloses a large and low cost portable raceway or vessel for holding flowable materials. The vessel has a body formed of an elongate rollable sheet of buoyant material that when assembled into an upwardly concave vessel has bulkheads at its ends to give it its half rounded shape. The large vessel is self-supporting in both water and land. The Warecki vessel suffers from a number of limitations.
Joining of parts such as bulkheads to the body of the vessel requires welding, chemical bonding, and/or mechanical fastening. Also, to maintain the shape of the pond, bulkhead bow frames must be positioned inside the vessel, dividing the space into closed compartments that are fastened mechanically or chemically to the body, although some unsecured movable compartments are used.
World Patent No.W02011016735 to Dalrymple discloses an erectable trough for animal feed.
The plastic sheet disclosed by Darlymple is bent into a U-shaped trough with opposite side walls being supported upright by tension wires through perforations in the side walls. As disclosed, the trough is not waterproof and not suitable for a raceway.
U.S. Pat. No. 5,846,816 to Forth ("Forth") discloses a biomass production apparatus includes a transparent chamber which has an inverted, triangular cross-section.
Although the Forth bioreactor promotes the growth of biological matter, it contradicts the principles extensively tested by Tredici, Fraunhofer and National Labs that assert the need to maximize exposed surface area relative to the volume displaced. Furthermore, the disclosed chamber is expensive to manufacture. Finally, the constant circulation of the liquid required by Forth interfers with the growth of some types of biological matter. For instance, fully differentiated aquatic plants from the lemnaceae or "duckweed" family are fresh-water plants that grow best on the surface of the water. Such surface growing plants typically prefer relatively still water to support and promote optimal growth.
To overcome limitations of prior art, the present invention seeks to provide an improved raceway-type pond with features of a photo bioreactor system that maximize the surface area exposed to sunlight in relation to the volume of algal solution; additionally, the invention seeks to provide a closable pond that promotes the growth of plant biological materials in a relatively sterile environment isolated from contaminants.
Furthermore, to reduce land usage, the present invention teaches an improved transparent/translucent hybrid raceway-type pond/photo bioreactor positionable in an elevated structure to maximize exposure to sunlight from all directions including from the underside which receives additional light from a solar reflector system.
Additionally, to overcome the high costs associated with most bioreactor designs and their short life expectancy, a worldwide problem that is impairing the commercial scale-up of the technology, the invention discloses a cost-effective transparent/translucent material such as, but not limited to, a durable, elongate, rollable flat sheet of semi-rigid fiber reinforced plastics (FRP) that may be re-shaped to become a hard thin-shell body to withstand stresses put on the elevated and suspended pond. It is known that FRP has a life expectancy beyond 10 to 25 years and that it can be produced in conventional production facilities cost-effectively.
Furthermore, to further reduce costs of production, transport, storage, distribution, handling and installation, the FRP sheets of the invention are configured to be thin enough to be rollable but rigid enough to withstand tough weather conditions and bending stresses. The rollability of thin FRP enables its borders to be bent so that they can engage into a repeating pattern of shape sustaining self-locking braces that maintains the shape of the pond.
Finally, by inserting, incorporating or attaching a number of thin sensors, detectors, wires, LED tapes, closable portholes, reflector films and other related equipment to laminar films that are incorporated to the FRP sheets during manufacturing, it is possible to further reduce costs of operation, control and monitoring of the system during operations.
And not the least, to overcome the generally high energy demand of prior art microalgae farming systems, the pond of the invention is provided with a low-energy demanding agitator and Light Emitting Diodes to provide artificial light during dark hours.
SUMMARY OF THE INVENTION
According to an embodiment, the invention is a repeating pattern of c-shape braces that have a generally flat portion flanked between two curved sidewalls each ending with a reverse bend. Engaging a flat sheet of semi-rigid material without tools or fasteners inside the shape-sustaining braces converts the flat sheet into an elongate receptacle-like thin-shell body such as a pond able to withstand higher bending stresses than typical.
According to another embodiment, the invention is a fast erectable closable transparent/translucent raceway-type pond having some features of a photo bioreactor system. The pond is comprising a transparent/translucent semi-rigid rollable sheet which shape is sustained by a repeating pattern of braces that imparted their shape to the pond.
Besides the general form of the braces, two other factors determine the size and shape of the braces: the length of the braces is substantially similar than the width of the semi-rigid sheet and the ends of the braces are provided with a reverse bend. These reverse bends create a self-locking effect that secure tightly the sheet edges into the braces.
It is known that raising borders of a semi-rigid sheet and maintaining such a shape throughout the length of the sheet stiffens that sheet. In this invention, the combination sheet, braces of the invention and their reverse bends creates a thin-shell structure able to convert bending stresses into tension and compression stresses enabling the structure to act more like a pre-tensioned beam rather than a plate. Consequently, disclosing a stronger pond that requires less material and less support than typical structures provides a more cost-effective solution for commercial scale-up of biomass production.
In a further embodiment of the invention, the combination sheet and braces enables to rapidly erect a pond from a substantially compact condition such as a roll, into a fully expanded condition such as an elongate pond. Such a feature reduces costs of storage, transport and time for installation. Furthermore, providing a pond that is translucent or transparent/translucent enables the pond to receive sunlight from all directions, thus increasing photon intake. To further reduce land usage, the pond may be suspended to or supported by load-carrying structures such as arc-shape, gothic-shape, reverse u-shape, A-shape or T-shape structures or to greenhouse and warehouse frames and structures of the like.
In an embodiment of the invention, the length of braces sidewalls is kept short on both sides.
Consequently, the sheet engaged in the repeating pattern of such braces defines an open pond. To close the pond, a removable, sealable and rollable cover is provided.
The cover may include components such as, but not limited to, connectors, sensors, detectors and portholes for oxygen removal.
In another embodiment of the invention, braces sidewalls extend to meet over the middle portion of the pond. Therefore, the sheet engaged in these braces takes the shape of a pond having two semi-covers closable at mid-point of the pond by a sealable profile.
In yet another embodiment of the invention, one of the braces sidewalls extends and overlaps the other side shorter sidewall. In this arrangement, the overlapping sheet engaged in those braces is also closable by a sealable profile.
According to another embodiment, the pond is floating over water and is supported by floats and buoys and by inflatable buoyancy units that may lower or elevate the pond, making exit of an aqueous solution and media contained in the pond more effective.
Alternately, the pond floats over water without requiring support from floats or buoys.
Preferably, all ponds of the invention are agitated by either a paddle wheel, a pump that circulates water or a wave generator that rotates an axle provided with a mechanism that generates a reciprocating up and down motion. The wave generator comprises a repeating pattern of eccentric cams that move up and down a pond support means, such as a cable or a chain, that supports one side or both sides of the pond.
In all embodiments of the invention, the sheet borders or the sealable profile that cooperates with said borders may include Light Emitting Diodes, sensors and detectors.
According to another embodiment, the pond of the invention includes a dewatering system defined by a sleeve filled with an aqueous solution and media for biomass growth. The sleeve is made of a transparent plastic film on the upper side and of an osmosis membrane on the lower side. In this embodiment, the sleeve is floating over a salty water of higher concentration than the aqueous solution in the sleeve. Dewatering takes place when the water content in the sleeve permeates into the salty water. Later, the biomass paste remaining inside the sleeve after dewatering is extracted by squeezing the sleeve and its content with rollers.
Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a roll being erected into a receptacle.
FIG. 2 is a perspective view of an open bioreactor with a cover.
FIG. 3 is a perspective view of a sheet curved to incorporate its own cover.
FIG. 4 is a perspective view of a sheet curved with one side overlapping the other.
FIG. 5 is a cross-sectional view of a detail of FIG. 4 FIG. 6 is a perspective view of multiple bioreactors supported by an A-shape structure.
FIG. 7 is a perspective view of a floatable bioreactor including a sleeve inside. FIG. 8 is a perspective view of two ponds supported by an arc-shape structure.
FIG. 9 is a front view of a double-wall pond with a water jacket supported by a U-structure.
FIG. 10 is a side view of a sleeve incorporating a flexible sparger.
DETAILED DESCRIPTION OF THE INVENTION
It will be appreciated that the present invention may be used to produce biomass of various types and forms or products derived from the biomass. The term "biomass" as used herein includes all organisms capable of photosynthetic growth such as plant cells and microorganisms (including algae and euglena) in unicellular or multicellular form that are capable of growth in a liquid phase. The term may also include organisms modified artificially or by gene manipulation.
The terms "receptacle", "bioreactor" and "pond" are used interchangeably in this invention to refer to any waterproof enclosure, container, chamber, vessel, canal, pipe, trough, tank, solar sill, desalination tank, gutter and other U-shape containers that are shaped by the braces of the invention able to contain a flowable material including organisms capable of photosynthetic growth. And more particularly, the term bioreactor refers to raceway-type ponds and photobioreactors also known as AlgaReactorTm (is a Trade Mark and a URL
Domain name of S. Mottahedeh).
The present invention discloses a fast erectable closable pond having features of a photo bio-reactor (PBR) that use light to grow a photosynthetic biomass such as a microalgae.
According to some embodiments of the invention, the fast erectable pond is made of a durable, resistant and long lasting semi-rigid thin material such as, but not limited to, Fiber Reinforced Plastic (FRP) that take on both a compact condition such as being reduced to a roll and an expanded or erected condition such as taking the shape of an elongate pond.
In the preferred embodiment of the invention, a semi-rigid sheet is rigidized by raising and curving said sheet borders and by engaging them inside a repeating pattern of c-shape braces sized with an interior perimeter substantially similar to the width of the sheet. The word 'c-shape' is used here to mean any kind of geometrical shape, including but not limited to square, rectangular, elliptical or curved in any other way, and the word `c-shape brace' will be referred to as 'brace' to express the same meaning.
Braces of the invention are configured with a generally flat base portion flanked between two curved sidewalls each ending with a reverse bend. By girding and bracing a semi-rigid sheet inside a brace and then by locking the movement of the sheet by a reverse bend system enables to transfer bending stresses exposed to the sheet into compression and tension stresses that are generally well withstood particularly by glass fibers and the polyester resins present in FRP sheets. Consequently, the combination sheet and braces of the invention defines a pond that requires less support than other pond structures therefore providing a more cost-effective solution for commercial scale-up of biomass production from microalgae.
Preferably, braces are located at equal distance in a repeating pattern to sustain the shape of the pond along the pond.
In a preferred embodiment of the invention, the fast erectable pond is configured with braces having sidewalls ending short on both sides. Consequently, the sheet engaged in such braces defines an open pond. To close such a pond, a removable, sealable and preferably rollable cover is provided. The cover may include components such as, but not limited to, connectors, sensors, detectors and portholes for oxygen removal. The cover, also made of a rollable semi-rigid material includes closable apertures. To ensure a tight closure during high winds, a strap is further provided to wrap around the cover and the pond.
In another embodiment of the invention, one of the braces sidewalls extends over the pond to overlap the opposite shorter sidewall. A semi-rigid sheet engaged in such braces defines a pond having its own integrated cover using a single sheet. Such a cover is liftable for providing access to the pond inner space.
In the above embodiment, one end of the combination sheet and braces is fastened to an elonagte sealable profile that engages sealingly with the other end of the same combination for enabling the opening and full closure of the pond. This elongate sealable profile includes cavities and bulges for holding equipment to enhance the growth of biomass.
Such equipment include, but not limited to, fastenable hangers that extend into said pond to support equipment, spargers, flexible wires, sensors, monitors, detectors, connectors, Light Emitting Diodes (LED) tapes or strips, computer chips, opto-electronic sensors, bluetooth (RF)-based short-range connectivity, photovoltaic cells, batteries, microplate readers and a combination thereof.
In another preferred embodiment of the invention, the pond includes a cooling or heating system comprising an arrangement of a second layer of a rollable semi-rigid transparent/translucent sheet of substantially same width that is inserted and engaged fittingly into the same braces of the invention over the first semi-rigid sheet already engaged fittingly inside the braces. The bottom portion of overlaid sheets is kept slightly apart by a transparent spacer positioned in between them. The spacer has cavities for circulating a fluid therein, thereby creating a water jacket.
Preferably, all semi-rigid rollable materials provided in the present invention are best made of materials selected from the group consisting of transparent/translucent or translucent materials selected from the group consisting of, Fiber Reinforced Plastic (FRP), Low Density Polyethylene (LDPE), High Density Polyethylene (HOPE), Rigid acrylic (PMMA), Poly vinyl chloride (PVC), composite plastics and of a combination thereof.
The word 'transparent' is used here to mean any degree of transparency, including but not limited to translucent materials and all materials transparent to visible light.
Preferably, braces are best made of materials selected from the group consisting of thin-gauge metal strips stiffened by ribs, of rigid fiberglass blanks, of wood laminates, of plastic composites, of cementitious material such as clay, ceramics, glass, of fiber cement and of a combination thereof.
To maximize exposure of a pond to solar radiation, the pond of the invention is made of a transparent/translucent material and is positioned in an elevated site relative to the ground or relative to a surface of water, so as to enhance maximum capture of photons from all directions including light that may be captivated from the pond underside.
To keep the pond in an elevated position, the pond braces are supported by a number of support means positioned either under the braces or on the side of braces. In one embodiment, braces are suspended on one side by chain or cable means and on the other side are secured by clamp means to fixed members. This arrangement enables, from one side, to modify the height of a pond to achieve a reasonable water level throughout the length of the pond, and from the other side, to agitate the pond with an up and down motion via a reciprocating mechanism, defined as a wave generator.
The support means mentioned above are cooperating securely with load-carrying structures selected from the group consisting of a reverse U-shape structure, an A-shape structure, a T-shape structure, a gothic-shape structure, an arc-shape structure, a greenhouse structure and a combination thereof.
To further increase photon capture by a pond, a reflective film or other reflective materials such as paint or reflective minerals are laid on the ground under the pond.
The solar light reflector of the invention is positioned slightly sideways under the pond to reflect solar light towards the pond underside. This solar light reflector comprises a reflective film suspended between two tension wires in a manner that the film adopts a substantially parabolic-shape curve that directs solar radiation to the underside of the pond.
For locations where the cost of land is expensive, or to reduce land usage in general, it is preferable to maximize the exposed surface relative to the pond footprint. To achieve this, a multi-level arrangement of staggered ponds is taught by this invention. In an example, multiple ponds may be supported by arc-shape or gothic support means such as supports provided in a greenhouse.
In an example of a modular load-carrying structure, a reverse u-shape structure carrying a single pond is also configured to cooperate like a scaffold with other reverse u-shape structures to collectively create a multi-stage pond system. The u-shape structure is comprising a repeating pattern of horizontal bars, each having ends secured to two vertical bars or pipes enabling the horizontal bar to be height adjustable via a clamp-type arrangement. In such a modular system, ponds are staggered to capture maximum amount of light during sunlight hours with minimum shade. The solar reflector of the invention is configured to reduce this shade by illuminating the underside of the ponds.
In another example, multiple ponds may be supported by an A-shape load-carrying structure comprising of two converging members that support a horizontal arm that hinges at a point located substantially between a short portion of said arm and a long portion;
the end of the arm long portion is supported by a vertical member securing an axle transmitting a reciprocating up and down motion to the horizontal arm.
By providing a counterweight positioned at the end of the horizontal arm short portion, some of the weight of the ponds may be offset. This minimizes the amount of energy needed by the horizontal arm to agitate the ponds and consequently by the reciprocating up and down mechanism and by the motor that drives it. By phasing out gradually, such as at 90 degree angle, the up and down movement of the horizontal arm along the transmission axle and along the connecting points of the repeating pattern of up and down mechanism, it is possible to reduce substantially the amount of energy needed to agitate the ponds. For example, for a 90 degree rotation of the axle, the first horizontal arm is pushed up, the second arm is pushed forward, the third is pushed down and the fourth arm is pushed backward.
Agitation of the aqueous solution with media may also be achieved by the traditional water wheel. In this invention, the horizontal axis of the water wheel is made to rest over the pond sidewalls with a casing configured to cooperate sealingly with the pond cover.
In another embodiment of the invention, a pond is supported over a span of water by floats or buoys and preferably by multiple inflatable buoyancy units able to lower and elevate the pond for easy exit from the pond of an aqueous solution and media contained in the pond. In this embodiment, the pond is kept slightly elevated from a surface of water such as the sea, said water surface being also covered by a floating reflector such as a bubble-film reflector. This arrangement provides multiple advantages. The natural movement of waves in a sea provides the desired agitation required to grow microalgae. Placing a light reflecting film floating underneath a pond reduces substantially the amount of "blackness" and "light absorption"
effect of the sea. Also, the bubble-film reflector enhances solar light reflection. Both of said effects increase photon capture by the pond. Also, as land usage is becoming more expensive with increasing population, using more ocean surfaces is becoming more prevalent. Additionally, the cooling effect of surrounding ocean water keeps temperature of the pond stable.
And finally, salt water being of higher concentration than sweet water such as from a water treatment plant, may be used to dewater a continuous flow or a batch-by-batch volume of an aqueous solution containing media for biomass production. In the present invention, seawater is introduced into the pond and the sleeve is made to float inside the pond over said seawater. By providing the sleeve with an osmosis membrane, the semi-liquid media containing biomass in the sleeve is gradually dewatered.
To best enhance biomass growth, multiple smaller length of sleeve portions like elongate bags containing batches of aqueous solution with media are attached together and are made to follow each other, similar to long detachable sausages that are gradually floated to mature over the pond on fresh water or salty water. The elongate bags are slowly moved forward, collectively or one by one, until the biomass reaches a mature stage where they are individually detached, retrieved from the pond and squeezed to extract the biomass paste from which oil will be extracted.
NASA developed a similar osmosis process called the OMEGA project. The difference between the OMEGA project and the pond system of the invention is that dewatering in the OMEGA project takes place with the sleeve fully immersed or in direct contact with the ocean, whereas in the present invention, the sleeve remains constantly in the pond that may be located anywhere on land. In the present invention, all parameters enhancing the growth of the biomass may be controlled, on land, during the biomass growth and the dewatering process. Additionally, a pond system such as raceway-type pond may be extended first in a direction away from the shore and then back towards the shore enabling to maintain full control of the entire process on firm land base. Furthermore, providing the pond with spargers, artificial light from Light Emitting Diodes (LED) during dark hours, sensors and detectors increases substantially biomass production level.
In yet another embodiment of the invention, the pond further includes a combination of a sterilized disposable transparent plastic sleeve with an integral disposable sparger in it. In this embodiment of the invention, growing biomass in such a disposable sterilized combination sleeve and disposable sparger positioned inside the pond obsoletes the need to clean the pond, provides a sterilized environment for growing sensitive microalgae species, shields the pond content against contamination from outside elements and enables quick access to the biomass by squeezing the sleeve by roller means to extract its content. It is known that sterilization of plastic bags is readily achieved by gamma rays.
In a further embodiment of the invention, the pond including an aqueous solution with media incorporates a dewatering system. The dewatering system consists of a half empty tube made of an osmosis membrane that contains salt water. Positioning said osmotic tube in the pond, absorbs by osmosis the sweet water from the biomass, causing it to dewater. The osmotic tube may be made large enough to line up the entire bottom part of a portion of the pond, so that the aqueous solution with media my rest on it.
In other embodiments, to supplement solar radiation during dark hours, the pond further includes artificial light by means of Light Emitting Diodes (LED).
Referring now to the figures and in particular to FIG. 1, a pond 10 best made of a semi-rigid material 12 is compacted into a roll 22 for easy storage, transport and installation in a first condition and is readily expanded into an erect condition such as to create a pond 10. Braces 1010 give to the pond its shape.
Referring now to FIG. 2, a preferred embodiment of an open pond is shown wherein pond 10 is comprising a semi-rigid sheet 12 shaped by a repeating pattern of shape-sustaining braces 110 that have a generally flat base portion flanked between two curved sidewalls each ending with a reverse bend 112 and 114. Pond 10 is provided with a cover 50 best made also of a rollable semi-rigid material. Cover 50 is provided with portholes 52 configured to connect to tubes for oxygen removal or for other purposes such as, but not limited to, looking into the pond 12 through lenses, hanging instruments, inputting nutrients, extracting samples or other usage. Naturally, these holes are not open directly to open air which may contaminate the pond 12 content but have air seals. Hangers 30 may attach to the sheet 12 sidewalls.
Hangers 30 may hold equipment such as a sparger 32 or sensors and detectors such as for pH or temperature control (not shown). Borders of sheet 12 are provided with a sealing means 60 such as a tape to seal the cover 50. A strap (not shown) is used to secure cover 50 and lean against sidewalls of pond 12 to withstand all weather conditions.
FIG. 3 refers to another embodiment of the invention wherein pond 10 is comprising of a semi-rigid sheet 12 shaped by a repeating pattern of braces 110 which sidewalls end 112 and 114 meet almost end-to-end at a central location. A sealing profile 70 secures sealingly the two semi-cover portions against any leakage or environmental contamination.
Pond 10 is supported on one side by clamps 116 and on the other side by suspension means 60. Clamps 116 are slidable over members of support means 80, such as member 82 from an A-frame (see FIG. 6).
Now referring to FIGS. 4, 5 and 7, yet another embodiment of pond 10 is shaped by a repeating pattern of braces 110 configured for braces end 112 to overlap braces other end 114. In this arrangement, pond 10 is provided with its own integral cover 50 created by extending one side of sheet 12 to cover and overlap the other side of sheet 10. Cover 50 is liftable on one side providing access to the pond content. An elongate sealing profile 70 is configured to secure, seal and lock together overlapping borders of sheet 12.
FIG. 5 shows more closely the cross-sectional profile of sealing profile 70 in the bubble A-A. Sealing profile 70 incorporates cavities and bulges 72 for securing equipment that enhance biomass growth in pond 10 such as tapes or strips of Light Emitting Diodes (LED) (40), fastenable hangers (30), spargers (30), flexible wires, sensors, monitors, detectors, connectors, (LED), computer chips, opto-electronic sensors, bluetooth (RF)-based short-range connectivity, transparent or opaque photovoltaic cells, batteries, microplate readers and a combination thereof.
In all embodiments of the invention, any or all equipment inserted, attached or incorporated in laminar form or in other forms to the semi-rigid sheets 12 and 50 of the invention during manufacturing or for other reasons may remain, preferably or if necessary, integrally attached to the sheet 12 when the sheet 12 is rolled for transport or storage reasons.
As mentioned earlier, some equipment such as reflective films, tapes incorporating sensors and detectors, LED tapes, wires 40, transparent or opaque photovoltaic cells or laminates of the like may be integrally built into the semi-rigid sheet 12 during the manufacturing process.
This integration is easily achievable for Fiber Reinforced Plastics (FRP) sheets 12 that already use laminated sheets as part of their manufacturing process. In an example, bands of reflective material 120 or of sensors (not shown) may be integrated at strategic locations into the FRP sheets 12 during manufacturing.
Now, as shown in FIGS. 6 and 8, multiple ponds 10 may be supported by load-carrying supports such as presented in pond system 1000 which is composed of a repeating pattern of individual support structures 80, each being configured to secure a repeating pattern of braces 110 that provide collectively a shape-sustaining support to each of the semi-rigid sheet 12 that define ponds 10.
Now referring particularly to FIG. 6, the pond system 1000 is composed of a repeating pattern of load-carrying A-shape structures, each comprising two converging members 82 and 84 that collectively support a horizontal arm 86-88 that hinges at a pivotal point located between a short portion 88 of the arm and a long portion 86, with the arm long portion 86 end being supported by a vertical member 81 that cooperates with an axle 210 that transmits a reciprocating up and down motion to the horizontal arm 86-88. Axle 210 is rotated by a drive means 220 which rotation speed is adjustable. To reduce the amount of energy required to drive motor 220 that moves the reciprocating mechanism 200, a counterweight 90 is suspended at the end of horizontal arm short portion 88.
Clustering ponds 10 together increases the total solar exposure of the biomass-producing area relative to the area of the pond footprint and reduces overall structural support costs. As shown in FIG. 6, ponds 10 are positioned in elevated locations and are staggered along an oblique line such as on member 82 to reduce shadow from other ponds 10. To reduce the shadow effect, a reflector 120 is positioned to reflect a more even distribution of solar radiation to the underside of ponds 10.
Other forms, sizes and shapes of load-carrying structures may be used. Such structures may include, but are not limited to, U-shape structures, T-shape structures, gothic-shape structures, greenhouse structures, warehouse structures or a combination thereof.
In an example of a modular load-carrying structure 80 as shown in FIG. 9, a reverse u-shape structure 80 carries a single pond 12 and is configured to cooperate like a scaffold system with similar reverse U-shape structures forming collectively create multi-stage pond systems 1000. The modular U-shape structure 80 is comprising a repeating pattern of height adjustable horizontal bars 81, each having ends secured to two vertical bars or pipes 83 and 85 secured to the horizontal bar 81 by a bolt via a clamp-type arrangement. In such a modular system 80, ponds are staggered to capture maximum amount of photons during sunlight hours with minimum shading affecting each other. The solar reflector of the invention 120 (not shown in this figure) is configured to reduce shade by illuminating the underside of the ponds 10.
Referring to FIG. 7, the lower film in sleeve 20 may be made of an osmotic membrane 320 configured to float over a span of salty water 16 covering partially pond 10.
As mentioned before, through the osmosis process, sweet water 18 contained in the aqueous solution permeates through the osmotic membrane 320 seeking to join the higher concentrated salt water 16 and in the process dewatering of the biomass grown in sleeve 20 takes place.
Alternately, instead of having sea water outside sleeve 20, sea water may be contained in an osmotic sleeve (not shown) made entirely of an osmotic membrane 320. Such an osmotic sleeve may be laid in direct contact with the aqueous solution 18 and media to dewater it.
In still another embodiment of the invention shown in FIG. 7, a floating pond 10 has braces 110 secured to floats, buoys or to buoyancy units 400. Some of buoyancy units 400 are inflatable so as to elevate or lower the pond 10 to enhance easy extraction of an aqueous solution and media contained in pond 10.
FIG. 8 refers to a repeating pattern of arc-shape load-carrying structure 80 that collectively support a pond system 1000 composed of two ponds 10 adjacent to each other and configured to counter-balance other each weight. Aqueous and biomass load carried by adjacent braces 110 associated to said adjacent ponds 10 may be counter-balanced by positioning said braces 110 on a pivoting arm (not shown) moved by axle 210 or by suspending one side of each of said adjacent braces 110 to a suspension means 60. The suspension 60 may in turn be moved by a reciprocating mechanism 200 that is rotated by axle 210. Similar to other embodiments of the invention, agitation of multiple ponds 10 may be achieved by securing one side of each pond 10 to clamp means 116, and by supporting, suspending or connecting the other side of pond 10 to the reciprocating mechanism 200.
Clamps 116 are affixed to braces 110 either hingingly, directly by welding or by rivet means or via tie means. Clamps 116 enable to achieve height adjustment of braces 110 and therefore of water level of ponds 10 along the full length of one side of a pond 10. A
similar adjustment of height is achievable by adjusting the length of suspension means 60 on the other side of braces 110.
FIG. 9 refers to another preferred embodiment of the invention wherein pond 10 includes a cooling or heating system comprising of a second layer of a rollable semi-rigid transparent/translucent sheet 22 laid over the first semi-rigid sheet 12 engaged already fittingly inside the same repeating patterns of braces 110. Said second sheet 22 has substantially the same width than the first sheet 12 and is also engaged fittingly into the same braces 110 of the invention at same locations. The lower portions of the two layers of sheets 12 and 22 are kept slightly apart by a transparent spacer 24 positioned in between the first sheet12 and the second sheet 22. The transparent spacer 24 has cavities for circulating a fluid 26 therein, thereby creating a water jacket.
A spacer 24 having cavities for circulating a fluid therein may include a thin multi-wall panel with space in between walls and enough wall thickness to withstand the load carried by pond exerted from the aqueous solution 18 with biomass. Wall shapes may include vertical-shape, zig-zag-shape, square-shape, wave-shape, 0-shape, cylindrical-shape, Z-shape and similar wall shapes of the like. Preferably, spacer 24 is also rollable for reducing transport and storage costs of pond 10.
Now FIG. 10 refers to a transparent sleeve 20 filled with an aqueous solution and media 18 for growing biomass. Sleeve 20 is comprising of a transparent film 310 cooperating sealingly with a flexible sparger 32, both being disposable and preferably made of biodegradable plastic. Flexible sparger 32 may be sealingly heat welded to plastic 310.
Alternately, instead of having sea water outside of sleeve 20, sea water may be contained in an osmotic sleeve (not shown) fully made of an osmotic membrane 320. The osmotic sleeve is brought in direct contact with the aqueous solution 18 and media to dewater it. The osmotic sleeve with sea water may come in direct contact with the aqueous solution and biomass inside of sleeve 20 or inside pond 10 without the presence of sleeve 20.
Certain features of this invention may sometimes be used to advantage without a corresponding use of the other features. While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
Claims (20)
1. A fast erectable bioreactor for biomass production comprising:
a) An elongate rollable flat sheet of semi-rigid transparent/translucent material having a substantially compact condition and a substantially erect condition, wherein in the substantially compact condition the sheet is reduced into a roll and wherein in the substantially erect condition, the sheet is converted into a receptacle by raising upwardly said sheet borders forming two substantially curved sidewalls which shape is sustained by b) a repeating pattern of braces, said braces sized with an interior perimeter of substantially similar length than the width of the sheet and configured with a generally flat base portion flanked between two curved sidewalls, each sidewall ending with a reverse bend, and c) two sealable bulkheads;
the bioreactor rapidly erected by engaging fittingly the sheet into said braces and by sealably securing said bulkheads to said sheet.
a) An elongate rollable flat sheet of semi-rigid transparent/translucent material having a substantially compact condition and a substantially erect condition, wherein in the substantially compact condition the sheet is reduced into a roll and wherein in the substantially erect condition, the sheet is converted into a receptacle by raising upwardly said sheet borders forming two substantially curved sidewalls which shape is sustained by b) a repeating pattern of braces, said braces sized with an interior perimeter of substantially similar length than the width of the sheet and configured with a generally flat base portion flanked between two curved sidewalls, each sidewall ending with a reverse bend, and c) two sealable bulkheads;
the bioreactor rapidly erected by engaging fittingly the sheet into said braces and by sealably securing said bulkheads to said sheet.
2. The bioreactor according to claim 1, wherein said combination rollable sheet, braces and bulkheads creates a rigidized receptacle such as, but not limited to, a raceway-type pond, a photo bioreactor, a vessel, a canal, a pipe, a trough, a fluid tank, a solar sill, a desalination tank, a gutter and a combination thereof.
3. The bioreactor according to claim 1, further including a cooling or heating system comprising a second layer of a rollable semi-rigid transparent/translucent sheet of substantially same width than said first sheet, said second sheet being engaged fittingly into said braces over said first sheet already engaged inside said same braces, said two sheet layers being spaced apart by a transparent spacer means positioned in between the two sheets flat base portions, said spacer having cavities for circulating a fluid therein, thereby creating a water jacket.
4. The bioreactor according to claim 1, further including a cover means, said cover means comprising a rollable transparent plastic sheet of semi-rigid material having borders cooperating sealingly with said sheet curved sidewalls, said cover including multiple closable apertures and equipment enhancing the growth of biomass.
5. The bioreactor according to claim 1, wherein one end of said braces sidewalls further extending to overlap the opposite end of said braces sidewalls; said braces imparting a substantially similar shape to a cooperating semi-rigid sheet engaged therein, said combination sheet and braces being liftable for providing access to the bioreactor inner space.
6. The bioreactor according to claim 5, wherein one end of the combination sheet and braces is fastened sealingly to an elongate sealable profile that engages sealingly with said combination opposite end enabling opening and closure of said bioreactor.
7. The bioreactor according to claim 6, wherein said elongate sealing profile further including cavities and bulges for holding equipment enhancing the growth of biomass, said equipment including, but not limited to, fastenable hangers extending into said bioreactor to support equipment, spargers, flexible wires, sensors, monitors, detectors, connectors, Light Emitting Diodes (LED) tapes or strips, computer chips, opto-electronic sensors, bluetooth (RF)-based short-range connectivity, photovoltaic cells, batteries, microplate readers and a combination thereof.
8. The bioreactor according to claim 1, wherein said semi-rigid rollable sheet is best made of, but not limited to, transparent/translucent materials selected from the group consisting of, Fiber Reinforced Plastic (FRP), Low Density Polyethylene (LDPE), High Density Polyethylene (HDPE), Rigid acrylic (PMMA), Poly vinyl chloride (PVC), composite plastics and a of a combination thereof.
9. The bioreactor according to claim 1, wherein said braces are best made of a material selected from the group consisting of thin-gauge metal segment stiffened by ribs, of rigid fiberglass blanks, of wood laminates, of plastic composites, of cementitious material such as clay, ceramics, glass, of fiber cement and of a combination thereof.
10. The bioreactor according to claim 1, wherein said braces are supported by and/or are suspended at an elevated position on a repeating pattern of load-carrying structures positioned at equal distance, said structures selected from the group consisting of reverse U-shape structures, A-shape structures, T-shape structures, gothic-shape structures, arc-shape structures, greenhouse structures, warehouse structures and of a combination thereof.
11. The bioreactor according to claim 10, wherein position of any of said ponds over said support structures is adjustable for easy adjustment of water level along the length of said bioreactor; said positioning achieved by clamp-type arrangement and/or by height adjustment of suspension means.
12. The bioreactor according to claim 1, wherein said aqueous solution with media contained in said bioreactor is agitated by an agitator means selected from the group consisting of an axle that transmits a reciprocating up and down motion to said bioreactor, a paddle wheel that keeps constantly the water in motion, a pump that circulates the solution and of a combination thereof.
13. The bioreactor according to claims 10 and 12, wherein the weight of bioreactors supported by said load-carrying structures is offset via connectors by weight of other bioreactors or by a counterweight for reducing the amount of energy needed to transmit a reciprocating up and down motion to the bioreactor.
14. The bioreactor according to claim 1, further including a solar light reflector comprising a reflective film suspended between two tension wires in a manner for the film to direct solar radiation to the underside of said bioreactors.
15. The bioreactor according to claim 1, further including a liner selected from the group consisting of a disposable transparent plastic film, a disposable transparent plastic sleeve, a combination sterilized disposable transparent sleeve with integral disposable sparger, an osmotic sleeve provided with a transparent flexible wall on the sleeve upper side and of an osmosis membrane on the sleeve bottom side, and of a combination thereof.
16. The bioreactor according to claim 15, wherein said bioreactor further including a dewatering apparatus comprising said sleeve with osmosis membrane filled with a first aqueous solution with media floating in said bioreactor over a second aqueous solution of higher concentration such as salt water; said first aqueous solution of lower concentration permeating through said membrane leaving behind a biomass paste, said biomass paste being squeezed out of said sleeve by an arrangement of roller means.
17. The bioreactor according to claim 1, wherein said bioreactor is floated over water by support means selected from the group of floats, buoys and inflatable buoyancy units able to lower or elevate the bioreactor for easy drainage of an aqueous solution and media contained therein.
18. The bioreactor according to claims 16 and 17, wherein multiple floating bioreactors, each further including said dewatering apparatus are moored to a land base; said dewatering apparatus comprising multiple attachable smaller autonomous sleeve portions collectively covering the length of the bioreactor, said dewatering apparatus further cooperating with said land base.
19. A fast erectable bioreactor for containing an aqueous solution and media for biomass production, said bioreactor comprising an elongate sheet of semi-rigid transparent material having borders raised to form two substantially short curved sidewalls which shape is sustained along the sheet by a repeating pattern of braces positioned at equal distance; said braces being sized with an interior perimeter substantially similar to the width of said sheet and configured with a generally flat base portion flanked between two curved sidewalls each sidewall ending with a reverse bend; said bioreactor sidewalls being covered by a sealable cover means incorporating portholes, sealing means, sensors, detectors and Light Emitting Diodes (LED), said bioreactor further including a sparger; the combination sheet, braces, cover and sparger defining a hybrid raceway-type pond/photobioreactor.
20. A fast erectable bioreactor including a cooling system for containing an aqueous solution and media for biomass production, said bioreactor comprising two elongate overlaid sheets of semi-rigid transparent/translucent material of substantially same width having borders raised to form four substantially short curved sidewalls which shape is sustained along the two sheets by a repeating pattern of braces positioned at equal distance; said braces being sized with an interior perimeter substantially similar to the width of said sheets and configured with a generally flat base portion flanked between two curved sidewalls each ending with a reverse bend; said two sheets flat base portions spaced apart by a transparent spacer inserted in between the sheets; said bioreactor covered by a sealable cover means.
Priority Applications (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2761251A CA2761251A1 (en) | 2011-12-07 | 2011-12-07 | Fast erectable bioreactor |
| PCT/CA2012/050750 WO2013082713A1 (en) | 2011-12-07 | 2012-10-22 | Low-cost photobioreactor |
| US14/362,904 US20140315290A1 (en) | 2011-12-07 | 2012-10-22 | Low-cost photobioreactor |
| CA2858204A CA2858204A1 (en) | 2011-12-07 | 2012-10-22 | Low-cost photobioreactor |
| AU2012350117A AU2012350117A1 (en) | 2011-12-07 | 2012-10-22 | Low-cost photobioreactor |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2761251A CA2761251A1 (en) | 2011-12-07 | 2011-12-07 | Fast erectable bioreactor |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2761251A1 true CA2761251A1 (en) | 2013-06-07 |
Family
ID=48570512
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2761251A Abandoned CA2761251A1 (en) | 2011-12-07 | 2011-12-07 | Fast erectable bioreactor |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2761251A1 (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2015056267A1 (en) * | 2013-10-14 | 2015-04-23 | Algalo Industries Ltd. | Algae growth system and method |
| WO2015106733A1 (en) * | 2014-01-17 | 2015-07-23 | Forschungszentrum Jülich GmbH | Photobioreactor and method for thin layer cultivation |
| WO2018019659A1 (en) * | 2016-07-29 | 2018-02-01 | Algowinn | Facility for culturing photosynthetic microorganisms, in particular microalgae, in a pond |
| FR3054562A1 (en) * | 2016-07-29 | 2018-02-02 | Algowinn | INSTALATION FOR THE BASIN CULTURE OF PHOTOSYNTHETIC MICROORGANISMS AND IN PARTICULAR MICRO ALGAE |
-
2011
- 2011-12-07 CA CA2761251A patent/CA2761251A1/en not_active Abandoned
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2015056267A1 (en) * | 2013-10-14 | 2015-04-23 | Algalo Industries Ltd. | Algae growth system and method |
| WO2015106733A1 (en) * | 2014-01-17 | 2015-07-23 | Forschungszentrum Jülich GmbH | Photobioreactor and method for thin layer cultivation |
| WO2018019659A1 (en) * | 2016-07-29 | 2018-02-01 | Algowinn | Facility for culturing photosynthetic microorganisms, in particular microalgae, in a pond |
| FR3054562A1 (en) * | 2016-07-29 | 2018-02-02 | Algowinn | INSTALATION FOR THE BASIN CULTURE OF PHOTOSYNTHETIC MICROORGANISMS AND IN PARTICULAR MICRO ALGAE |
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