WO2014182600A1 - Soil-less indoor farming for food and energy production, including high density three dimensional multi-layer farming, permeable three dimensional multi-layer farming and continuous flow farming of material products - Google Patents

Soil-less indoor farming for food and energy production, including high density three dimensional multi-layer farming, permeable three dimensional multi-layer farming and continuous flow farming of material products Download PDF

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WO2014182600A1
WO2014182600A1 PCT/US2014/036754 US2014036754W WO2014182600A1 WO 2014182600 A1 WO2014182600 A1 WO 2014182600A1 US 2014036754 W US2014036754 W US 2014036754W WO 2014182600 A1 WO2014182600 A1 WO 2014182600A1
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Prior art keywords
growth
farming
plant
layers
layer
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PCT/US2014/036754
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French (fr)
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Sadeg M. Faris
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Faris Sadeg M
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Priority claimed from US13/887,334 external-priority patent/US20140325908A1/en
Priority claimed from US13/887,333 external-priority patent/US9606553B2/en
Priority claimed from US13/887,337 external-priority patent/US20140325910A1/en
Priority claimed from US13/887,336 external-priority patent/US20140325909A1/en
Application filed by Faris Sadeg M filed Critical Faris Sadeg M
Publication of WO2014182600A1 publication Critical patent/WO2014182600A1/en

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    • AHUMAN NECESSITIES
    • A01AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01GHORTICULTURE; CULTIVATION OF VEGETABLES, FLOWERS, RICE, FRUIT, VINES, HOPS OR SEAWEED; FORESTRY; WATERING
    • A01G31/00Soilless cultivation, e.g. hydroponics
    • A01G31/02Special apparatus therefor
    • AHUMAN NECESSITIES
    • A01AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01CPLANTING; SOWING; FERTILISING
    • A01C1/00Apparatus, or methods of use thereof, for testing or treating seed, roots, or the like, prior to sowing or planting
    • A01C1/02Germinating apparatus; Determining germination capacity of seeds or the like
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P60/00Technologies relating to agriculture, livestock or agroalimentary industries
    • Y02P60/20Reduction of greenhouse gas [GHG] emissions in agriculture, e.g. CO2
    • Y02P60/21Dinitrogen oxide [N2O], e.g. using aquaponics, hydroponics or efficiency measures

Definitions

  • This invention relates to improvements in farming for food and energy production.
  • Plants store solar energy in the form molecular bond energies of carbohydrates, sugars, starches, cellulose and proteins.
  • the economics of conventional farming to profitably produce generally affordable staple foods (sugars, cereal grains, legumes, leafy vegetable, and tubers such as: potato, yams, cassava) relies directly on the zero cost of solar energy, ZCOE. This forces cultivation outdoors, on two dimensional lands, because the solar radiation is delivered in units of Watt per unit area (hectares, acres, or square meters).
  • FIG. 1A As is well known, since its invention, agriculture is generally practiced in the form depicted in FIG. 1A, two-dimensional outdoor soil-based farming. This includes the essential elements of food production: i)- the sun; ii)- 2D field, an area covered with soil that mechanically and physiologically support plant growth; and iii)-water irrigation source, and nutrients. This is referred to as arable land that combines adequate quantities of sun, water, and nutrients which generally come at no cost. The supplemental nutrients or fertilizers, when added, carry a relatively low cost. As demonstrated by AgriPAL described herein, this form of farming has been profitable because the main ingredients come at little or no cost.
  • CEA In recent years, the adoption of indoor controlled environment agriculture, CEA has increased.
  • An exemplary prior art reference is US Patent 3,931,695 which gives a good description of CEA.
  • the growth area In CEA, the growth area is sheltered, making the control of many plant growth parameters possible, thereby achieving higher yields and higher resource utilization efficiencies.
  • the increased use of soil-less hydroponic or aeroponics nutrient delivery practices increased the economic viability for growing many plants.
  • FIG. IB illustrates the elements of CEA, also referred to as greenhouse.
  • solar illumination When solar illumination is used, CEA is the same as conventional sheltered farming with the added benefit of protection from the weather and better control of pesticides, nutrients, and water.
  • yields can be enhanced and many planting cycles become possible year round.
  • artificial lighting When artificial lighting is used, extending growth periods to 24 hours per day becomes possible.
  • AgriPAL as discussed further herein in conjunction with the present invention, has shown that this growing method of farming, while growing in acceptance, is economically viable for certain high value added plants. It is not possible to economically (profitably) produce staple crop or biofuel using known indoor farming because of the added daily energy consumption for heating or cooling, and the cost of the added infrastructure.
  • the objects of the present invention are inventive aspects that make indoor farming viable even for staple foods.
  • the present invention addresses these limitations, by means of making growth layers in the form of networked strings that are coupled to each other sharing light, and nutrients, thereby compressing the vertical height needed for growth by factors ranging from 5 to 50.
  • FIGS. 1D-1H illustrate conventional plant growing methods having distinct environments, (elements) 50a-50e, each of which comprises, a plant 53 illuminated by sunlight 51. They are distinguished by the type of growing medium, the plant mechanical support, and the method of delivering nutrients to the plants. In the case of elements 50a, 50b and 50e, the soil provides the support and nutrients are delivered directly to the soil which are them up taken by plant roots.
  • the hydroponic method well known in the art comprising, a mechanical structure 54, (container) for growing one or more plants.
  • the container is filled intermittently (or continuously) with nutrients 55, and the plant up takes the nutrient through a porous root support structure, 52a.
  • This root support structure replaces soil.
  • the aeroponics method, 50d also known in the art, comprises a plant support structure 56, through which the roots penetrate to bottom space 57c, where the roots are sprayed directly by means of nozzle 57.
  • This method is known to achieve better yields than the soil based and the hydroponic systems because the roots are in direct contact with the ambient oxygen. Its main disadvantage is the low vertical space utilization efficiency and the spray nozzle clogging.
  • the roots are feed by a plurality of different physically separated components (discrete instead of integral components). Also all of these elements feed the roots indirectly from the bottom.
  • the present invention is related to the field of agriculture, horticulture, agronomy and agro-economics of food, energy, and other organism made substances. It is specifically related optimizing plant, yields, photosynthetic energy conversion efficiency as well as the utilization efficiencies of other resources, including, time, space, water, and nutrients. Even more specifically, the invention is related to indoor, environmental controlled farming in three dimensional (3D) spaces, vertical farming, without the reliance on the sun energy or soil.
  • 3D three dimensional
  • the invention also addresses the need to solve problems associated with conventional outdoor two dimensional farming which is projected to limit its ability to achieve food and energy security for humanity.
  • the present invention is related to 3D farming systems comprising a plurality of layers each of which is capable of sustaining the growth of plants.
  • the present invention is related to 3D farming systems in which the plurality of layers are permeable in the sense they can permit water, nutrients, light, shoot and roots of neighboring layers to pass through the layers.
  • the present invention is related to 3D soil-less farming for enhancing volumetric productivity and 3D yield by means of continuous flow agriculture capable of synchronous daily planting, harvesting and amplifying of material products, MP, including plant-made-products, PMP, and culture made products, CMP, used for food, biofuel, medicine, and high performance industrial materials.
  • the species used for the culture and production of CMP include individual living cells, microorganisms, employing cell methods of production.
  • the species can be naturally bred, wild, or genetically transformed by means of transient, plastid, or nuclear recombinant engineering methods.
  • the specific use of the word plant, as in plant layers, and plant growth elements, is not meant to limit the scope of the broad inventive features that apply generally to a broad spectrum of growing material products.
  • AgriPAL and PGM present for the first time, mathematical and analytical foundations, based on scientific principles, that describe how photosynthesis works, and presents formulas for predicting yield, energy efficiency, and agronomic profitability. They unraveled ceremonies that to date eluded and baffled plant scientists and agronomists. They revealed the notion of solar gain, and astonishingly high physiological gains which can be garnered by means of better underrating of resource utilization efficiencies. These gains increase the yields and efficiencies by more than 10 fold and a path to approach and exceed 100 fold.
  • the object of this invention is to teach means and methods to profitably harness the third dimension where unlimited space is available, where soil is avoided, and water can be conserved.
  • the inventive 3D agriculture according to the present invention focuses on utilizing the third dimension efficiency by teaching devices, systems and methods to compress the vertical space needed for food production.
  • the teachings according to the present invention of 3D farming is the partitioning of the third dimension into a plurality of layers (multi-layers) each of which is capable of being supplied with nutrients, and the light needed to sustain growth.
  • Said plurality of layers are supported by means of a 3D structure that comprises a master system comprising subsystems which are designed to optimally provide water, light, nutrients, C02, 02, and temperature controls for specific plant organism species.
  • Said plurality of layers comprise strings of interconnected soil-less (SanSSoil) growth elements, SGEs, each of which is integrally made to have a multi-function capability including: germinating the seed, growing the plant, providing the plant with physical structural support, water, nutrient, light, and capability to sense the plant environment.
  • SanSSoil soil-less
  • the strings of SGEs are disposed in the first, second and third spatial coordinates. They are in the form of one dimensional network, two dimensional network or three dimensional network supported by the multilayer structure.
  • An aspect of the invention is resource utilization efficiency such that staple foods and bio-energy are produced profitably so that the food and energy supplied with no "food or fuel” competition problem. This is accomplished by means of inventive features described herein that enable the plants in each SGE in string networks to share resources including: light, nutrients, and intra-layer space. This is the multi-layer permeability property taught according to certain embodiments of the present invention.
  • Another aspect of the present invention is making the each SGE and the string interconnection and space between strings optically transparent or permeable so as to enable light to pass through plurality of layers to share, conserve and efficiently utilize light. This will minimize the need for many light sources, thereby reducing product cost.
  • Another aspect of the present invention is avoidance limitations of prior art method of growing plants to reduce cost to enable economical staple food production.
  • Another aspect of the present invention is saving vertical, intra-layer space by enabling the plant root and plant shoot sharing. This means the roots of plants one layer, can occupy (share) the space of the shoots (leaves) of the layer below.
  • TSA traveling seed amplifier
  • system and method which enables high through put continuous flow farming of MP, that have wide spectrum of applications including: all foods, biofuel, medicines, and high performance industrial materials.
  • Key features of TSA include the continuous -synchronous or semi- continuous planting and harvesting MPs at high rates, ranging from 1 to 10 times per day, or at compressed time periods much shorter than the specie dependent seed to harvest time, r sth .
  • Another aspect of the present invention is compressing the vertical space resulting in much higher volumetric productivity, ton/hectare/meter, than prior art vertical concepts discussed above, and illustrated in FIG. 1 C.
  • there are at least three ways to achieve vertical compression of the average interlayer spacing h av which include: i)-the use of ultra-compact integrally constructed SGEs assembled in string networks; ii)- enabling the shoot-root space overlap; and iii)- the TSA system and method which automatically adjusts the traveling interlayer spacing according to the age of the growing plant.
  • Another aspect of the present invention is providing a totally sealed system for growing plants for food and energy comprising inventive sealing features and mechanisms to recycle water and nutrient resources to maximize utilization efficiency and reducing cost.
  • inventive sealing features and mechanisms to recycle water and nutrient resources to maximize utilization efficiency and reducing cost.
  • the natural transpiration of water is recaptured and reused.
  • the plant growth environment is maintained at a desired temperature and relative humidity for optimum plant performance.
  • the result is water saving by reutilizing between 100-1000 times water which would have been wasted in conventional outdoor agriculture.
  • Benefits of sealed 3D growing systems include the avoidance of the unpredictable weather conditions which results in a reliable food production with losses due to weather.
  • the sealed growing 3D system can be made aseptic, pathogen free, adding yet another path to profitability assurance.
  • Another aspect of the present invention is harnessing the limitless vertical space in combination with the TSA and continuous flow agriculture to construct high rise edifices, and tower structures extending upward tens of meters or even hundreds of meters in the sky, enabling the production of MP, food and bio-fuels without competition for space resources, since the vertical space is limitless.
  • the TSA towers may be illuminated by the sun, artificial lighting, such as LED, or a combination of both.
  • the second tower comprises a harvesting port (output) also at the bottom.
  • seed or seedling layers are inserted in the planting while mature plant layers are synchronously harvested from the harvesting port.
  • a transport means is provided to transport the layers from the planting port to the top of the first tower, transferring layers laterally to the top of the second tower, and finally transporting the layers downward for harvesting at the bottom harvesting post of said second tower.
  • TSA tower pairs featuring vertical compression factors in average interlayer spacing, h av , ranging between 2 and 10, and temporal
  • Yet another aspect of the present invention include sealed 3D growing system or TSA tower systems that are aseptically sealed by providing load locks to the planning and harvesting ports and automation means to control physiological and environmental and physical parameters for optimum MP growth conditions.
  • Another aspect of the present invention is the isolation of the sealed 3D growing system or sealed 3D growing TSA tower system from the external environment thereby protecting said environment. This is especially beneficial when growing genetically transformed plant species (GMO) for experimental and production purposes.
  • GMO genetically transformed plant species
  • Yet another aspect of the present invention is the ability of one layer to water, and nutrients from the strings of SGE in said layer, to strings of SGEs in the plurality of lower layers. This is a unique feeding mechanism that is distinct from well know prior art hydroponic and aeroponics mechanisms
  • Yet another aspect of the present invention is the utilization of artificial lighting, preferably LED, instead of solar lighting. More specifically, LED lighting that is delivered to the plants as pulses of short duration, between 0.1 ms and 2.5 ms, and frequencies between 30 Hz and 300 Hz. Applicant discovered that the enzymatic kinetics of the plant physiology can be made 4-10 times more efficient by temporal control the light.
  • Yet another aspect of the present invention is the control of the spatial placement of LED illumination sources within the 3D growing system in order to maintain uniform illumination received by the growing plants.
  • FIGS.1A-1 C describe conventional farming methods, including outdoor soil based farming, indoor CEA (greenhouse) farming and 3D vertical farming;
  • FIGS. 1D-1H illustrate the various environments which plants grow into and specifically how nutrients are delivered to the plant roots
  • FIGS.2A-2C show experimental photo synthetic response of two lettuce varieties and strawberry plants to the variation of light intensity, PAR, and carbon dioxide levels. These reveal the saturating or limit level phenomena of the inputs;
  • FIG. 2D is an illustration of the fine temperature control and its impact on the saturating response of photosynthesis
  • FIG. 2E shows the photosynthesis response of pulsed illumination at different periods, revealing a high cut off frequency analogous to a high pass filter
  • FIGS. 2F-2H illustrate the photo synthetic temporal responses of various plants under pulsed illuminations, revealing temporal gain factors ranging from ⁇ 3 to -10;
  • FIG. 3A illustrates a SansSoil indoor farming system comprising a protected environment for sustaining plant growth, and a control subsystem that follows a program to control the growth;
  • FIG. 3B-3C shows more details of the system of FIG. 3 A, that is comprised of multilayer each of which comprises a network of strings of SansSoil Growth Elements, SGEs, showing the localization of each element in the 3D space, first, second and third spatial coordinates, and how they periodically repeat with periods p x , p y , p z ;
  • FIG. 3D-3E describe more details how each SGE is made, its structures and function
  • FIGS. 3F-3K describe how SGE are interconnected into strings, which in turn from layers of plurality of strings all networked to from a 3D growing system shown with respect to FIG. 3A;
  • FIGS. 4A-4H describe the integrally made single SGE and its commutations with its neighbors sharing resources including light and nutrients to support growth;
  • FIGS. 4I-4M describe the integral SGE and SGE strings with plant growth in various orientations
  • FIG. 4N illustrates the possibility that strings of SGE may interconnected into series and parallel network combinations in communication with resource supply sources
  • FIG. 4P shows a plurality of exemplary configurations to attach SGE to supply sources, and to neighboring SGEs
  • FIGS 5A-5B illustrate SGEs allowing plants to grow upside-down
  • FIGS. 6A-6B illustrate delivery subsystems to multilayer SGE networked strings, showing light delivery from the support walls of the main structure;
  • FIGS. 6C-6E show main system housing protective structures configured to various sections;
  • FIG. 7A describes multi-layer permeability of light, enabling layers to share light from common source
  • FIGS. 7B-7C describe the multi-layer permeability of shoots, and roots sharing space of neighboring layers
  • FIG. 7D illustrates the multi-layer permeability to fluids delivering nutrients to plants from a common source, whereby the fluids are in the form of fog, mist, sprays, and streams;
  • FIG. 8A describes the multi-layer tower traveling seed amplifier, TSA, system for continuous flow agriculture
  • FIGS. 8B-8E describe typical plant growth trajectory curves, defining key parameters to illustrate the inter-layer vertical space compression system of TSA;
  • FIG. 8F describers the flexibility in locating the planting and harvesting ports attached to the TSA tower housing
  • FIG. 8G describes a variation of a TSA system wherein the layers move horizontally instead of vertically;
  • FIGS. 9A-9B illustrates the variable pitch screw TSA transport mechanism which automatically maintains appropriate interlayer spacing according to plant age
  • FIGS. 9C-9F describe an embodiment of a TSA system showing various components
  • FIGS. 10A-10D are illustrations of a composite TSA layer comprising a plurality of trays in the form of 2D SGE arrays for cell cultures on super-hydrophobic coatings;
  • FIG. 11 describes the diverse energy sources which may be used to drive the operation of the TSA tower, to drive strings of LED, control the climate and to deliver nutrients to sustain plant growth.
  • the present invention is generally related to growing or amplifying martial products, PM, including, PMP, and CMP.
  • PM including, PMP, and CMP.
  • the specific use of the word plant, as in plant layers, and plant growth elements, is not meant to limit the scope of the broad inventive features that apply generally to a broad spectrum of growing material products.
  • the term "SanSSoil” refers to an enclosed indoor farming method that eliminates the need for soil.
  • the sun is also optionally eliminated as the main light source for photosynthesis.
  • the sun may be used alone or in combination with artificial lights.
  • three dimensional architectures are found to be most advantageous. The use of the third dimension enables the productivity metric of yield per cubic meter to be used, and the means to maximize it are sought, leading to minimum use of land area.
  • inventive solutions presented herein have been inspired by Applicant's discovery of mathematical analytic expression, referred to as AgriPAL (agriculture profitability assurance law), which gives deep insight, for the first time, as to why conventional outdoor farming has been profitable since its invention ca 10,000 ago.
  • AgriPAL agricultural profitability assurance law
  • each cell has a water content of 60-80% of dry weight. It is possible to recycle all the water that is not stored part of the dry biomass. Therefore, using a totally sealed environment, the water requirement for farming can be reduced by at least two orders of magnitudes.
  • ⁇ ⁇ is not only species dependent, but also variety (cultivar) dependant. Each cultivar is optimized by breeding and propagation methods to exhibit desirable traits for specific geographical locations, and regional soil conditions. The growers, however, have no control over this outdoor parameter ⁇ ⁇ , once they purchase the seeds (embryos) suitable for their location and environment.
  • Applicant's AgriPAL is another contribution which links the physiological aspects of ⁇ ⁇ to the economic viability index for outdoor farming. It has enabled Applicant to teach herein several inventive embodiments related indoor farming which emulate the economic viability of outdoor farming as clarified by AgriPAL formula.
  • AgriPAL explicitly reveals EVI as the quantity: rj E g solar , with g sol as the solar gain, without which, farming is not profitable. It requires that J E g solar approach or exist 1, so that the condition in Eq. (1) is satisfied. Applicant derivation of the new AgriPAL reveals transparently, unambiguously, and explicitly, for the first time, role the sun plays in an agronomic formula even though the cost associated with solar energy is zero. It also enables the accurate accounting of all other energy sources, s other , which include, hydrocarbon, electrical, mechanical, and chemical sources.
  • This second premise of the invention is the method that made EVI transparent and explicit. It revealed for the first time, that even though the energy efficiency can be as low as 0.005 or even as low as 0.001(table 1), EVI as whole can approach the value of 1 and may even exceed 1, because g sol » ⁇ , enabling the profitability condition in Eq. (1) to be satisfied.
  • the solar gain factor g sol may exceed 1000, since it is possible to realize in certain situations s other to be very small, or even vanishingly small.
  • step g the mission to produce all foods and bio-fuels with no competition, according to conclusions 1-5 of the first premise, is now accomplished.
  • the third piece of the puzzle is predicated on the successful ability to achieve step d: Embark on research and analysis that will make the physiological and physical components ⁇ ⁇ more transparent, so as to enable us to fully account for all the losses and the bottlenecks and invent means and methods to transform and enhance ⁇ ⁇ , to become rf E ⁇ gj] E ⁇ EVI e . This is one of the key aspects of the present invention.
  • Parameters in, rf E ⁇ gj] E ⁇ EVV , that have small "e” refer to the enhancement required for indoor farming according to the present invention that satisfy the AgriPAL viability condition.
  • St (GJ m-2) is the total incident solar radiation across the growing season
  • s j is the light interception efficiency
  • s c is the conversion efficiency
  • ⁇ ⁇ is the partitioning efficiency also termed harvest index
  • the new model must be able to achieve step d of the third premise in order to successfully emulate the profitability success of solar-based outdoor farming. Even more specifically, the new model should enable to accurately measure the temporal and spatial aspects of the organism. Such an accurate model will enable scientists and engineers to provide innovative systems and methods that improve plant productivity, and ensure both food and energy security to do away with the "food or fuel” conflict.
  • step d of the third premise seeking an inventive method and means to emulate the profitability success of conventional solar energy-based outdoor farming requires the an enhanced energy conversion efficiency, ⁇ ⁇ > ⁇ ⁇ ⁇ realized, with an enhancement factor or gain factor defined by: rf E ⁇ gj] E ⁇ EVV .
  • Prior art teaching according to Eq. (2) does not reveal the requisite physiological transparency that even hints at the possibility of achieving a gain factor g e > 1.
  • the fifth premise is Applicant's Plant Growth Model, PGM, that has enough plant physiological details to enable engineers to conceive inventive farming methods and systems with g e > ⁇ .
  • PGM Plant Growth Model
  • the detailed derivation of PGM and its agronomic applications are presented in Section III.
  • the key inventive methods and means are embodied in the following equations:
  • One or more members of a group may be combined with members of one or more of the remaining groups to form a new group for the purpose of constructing a means and or method for achieving ⁇ gj] E ⁇ EVV , with g e > 1 , in order to satisfy the profitability condition AgriPAL for the present inventive indoor farming. This affords many levels of control and the ability to obtain the necessary gain to satisfy Eq. (1).
  • gain, g e > ⁇ and more specifically the gains in ranges 2-5; 5-10;
  • direct costs The latter are computed by the dividing them by a reference COE.
  • the energy equivalent direct costs so converted include components of / and v in Eq. (1), leaving only the indirect cost components of / and v in the right hand side of Eq. (1).
  • g e in the range of 5 to 10.
  • g e in the range of 10-100 can be derived from the enhanced % sp % t f group.
  • gain, g e > ⁇ and more specifically the gains in ranges 2-5; 5-10;
  • biomass derived energy must have >1.
  • inventive embodiments of the present application are based on the above five scientifically based premises. They afford deeper insight leading to a much improved understanding of the plant physiology, energy conversion efficiency and their relationship with temporal and spatial domains in the microscopic (micron, ms) and macroscopic (meters, hours days) scales. They provide transparency of the role each of plurality physiological parameters play, thereby, allowing engineers to identify and fix bottle necks in a focused manner.
  • the annual 2D yield (2D plant productivity) is measured in tons or kg per 2D area units (hectare, acre, or m2).
  • the 3D yield (3D volumetric productivity) is measured in units of kg per m3.
  • Profitability requires cultivating minimum land area about 250 hectares, in agronomically advanced regions.
  • the indoor 3D farming of sugar beet is energy efficient and profitable, then multi-layer 3D farming with 10 to 100 layers produces sugar for food and fermented into ethanol biofuel, without infringing on additional land. This alleviates the concern over more deforestation and resolving the food vs. fuel dilemma.
  • COE is the average cost of all input energy, sources directly used to produce the products, in units of, $/kWh
  • ROE is the average return on energy, revenues from energy contents of all the products produced at the prevailing market prices, in units of, $/kWh
  • p is the profit divided by the total energy cost
  • f is the total cost attributable to the fixed capital equipment expense, CAPEX, and other fixed costs, divided by the total energy cost
  • v is the total variable operating costs, OPEX, divided by the total energy cost.
  • AgriPAL described in Eq. (1) is energy centric in that all the terms are dimensionless ratios of energy quantities or ratios of cost of energy. Since food (energy for life) and energy in general are used synonymously in this treatment, AgriPAL is a valuable tool, that in this form, or in its more general from (not presented here), is used as an inventive algorithm for the determination of the economic viability and profitability if all food or energy producing enterprise. [175] AgriPAL states that unless that condition is met, the enterprise is not viable. For food and energy enterprises, it made the energy parameters transparent, and at a quick glance, a conclusion can be made. For example, even though, from Table 1, ⁇ ⁇ -0.005, the solar gain g sol
  • g sol > 200 also assures profitability, because the farmer relies of human and animal muscle energy intermittently, the quantity of which is negligible relative the quantity of solar energy absorbed and stored by the plant over 100 to 1000 day cycles.
  • AgriPAL states that unless that condition, in Eq. (1) is met, the enterprise is not viable. For food and energy enterprises, it made the energy parameters transparent, and at quick glance, enables one to reach interesting and valuable insight. It is a tool to help lower the risk of decision making: to launch a new enterprise, to expand, relocate, to improve product mix, to leverage product mix, compete better, to reduce cost by many means.
  • Eq. (2) For farming commodities (staple foods) including: cereals, soybean, sugar from sugarcane and sugar beet, tubers, potatoes, yams, and cassava, the right hand side of Eq. (2) can be shown to be at least 1.3 (marginally profitable enterprises).
  • the global market determines the commodity prices, which range between $0.25/kg and $0.5/kg. These crops have an average intrinsic energy content ⁇ $3kWh/kg.
  • the cost of diesel is ⁇ $0.08$/kWh, while the cost of solar energy is zero.
  • Example 5 The Profitability According to the Present Invention
  • Examples 2, 3, and 4 highlighted the challenges associated with growing staple commodity foods indoors, and why Example 1, outdoor field farming is the only presently available viable option for growing staple food to feed the world. This viable option is for the continuous reliance on the zero cost solar energy, and its associated drawbacks of large land and water requirement and their inefficient utilization.
  • the outdoor farming constraint subjects the growers to environmental risks of unexpected crop losses due to various factors, including: microscopic pathogens, weeds, droughts, floods, and extreme unseasonable temperature variations.
  • one of the main objects of this invention is presenting an alternative to outdoor solar based 2D farming.
  • the inventive farming systems and methods are based on the five premises presented in Section I that enable the replacement of the sun and its gain ⁇ z with artificial lighting and an enhancement gain g e . This will ensure profitability not only for staple food according to AgriPAL, but also enables the productions of all other crops with much higher profit margins than previously possible by prior art methods.
  • Section II there are presented a number of examples highlighting the challenges associated with growing staple commodity foods indoors, and why that is not possible if one relied of the limited prior art understanding of the efficiency, ⁇ ⁇ , concluding that outdoor field soil-based farming is the only presently available viable option for growing staple food to feed the world, and growing biofuel, energy for transportation.
  • AgriPAL takes the following three forms:
  • AgriPAL may also take an alternative form by incorporating in s other , the energy equivalents of / + v.
  • the three EVI expressions comprise the energy conversion efficiency ⁇ ⁇ .
  • Tools used include: Faster, cheaper genome sequencing, bio-engineered organisms that exhibit novel desirable traits encoded in their transformed genomes, plant cell culture, and accelerated breeding though double haploid technology to produce stable pure breeds.
  • the high value added products include: plant made materials, proteins, nutraceuticals, and pharmaceuticals, vaccines.
  • plant made materials proteins, nutraceuticals, and pharmaceuticals, vaccines.
  • guar gum from guar bean
  • the material is a polysaccharide possessing a highly prized unique rheological property. In addition to being food, the material is also used in personal care products.
  • Examples 2, 3, and 4 presented in Section II highlighted the challenges associated with growing staple commodity foods indoors relying on the limited prior art understanding of ⁇ ⁇ , ( s c , Eq. (2) Section I) , and why Example 1 , outdoor field farming is the only presently available viable option for growing staple food to feed the world.
  • A. Providing, for the first time, an analytical expression relating plant (organism) physiological efficiency and its direct impact on the economic viability for producing products from the plant.
  • the new PGM made the physiological conversion efficiency transparent by revealing large number of parameters which can be controlled, and a plurality of means to achieve g e by various combinations of controlling those physiological parameters from a large group.
  • the total biomass, BM, (living, or dead) produced by the photosynthetic conversion comprises various organic compounds, that together have an intrinsic average energy density, (energy content), s d in units of MJ/kg or kWh/kg.
  • energy content energy density
  • wheat biomass ranges from 3- 4kWh/kg
  • lettuce and spinach biomass the range is from 0.2-0.4kWh/kg.
  • the energy conversion efficiency, ⁇ ⁇ is the ratio of the output biomass energy content, to the total input energy during the seed-to-harvest time (growing cycle time), r sth , is described given by:
  • Y is the output biomass yield in units of (kg I m 2 1 year) , P sal v ' & the average photon power, in W7 m 2 , at photosynthetic saturation intensity from the sun, lamps, light emitting diodes, LED, or a combination thereof.
  • Living organisms include: plants, animals, and fungi ranging in size from the unicellular micro-organisms including: algae, yeast, bacteria and cyano-bacteria, to mammoth sizes such as the 100 m high Sequoia tree and the 200 ton blue whale. I have discovered that the growth dynamics of all of these living organisms are solutions to rate equations derived from energy and mass conservation laws.
  • G BM (t) G BM ( ⁇ )( ⁇ - e- Kt ) (8)
  • (l - e ⁇ Kt ) is a composite growth function that saturates to an average maximum mass, G MB ( ⁇ ) , at a rate K, both quantities (pheno types) are determined by the genome of a specie's many cultivars or varieties.
  • the growth function is the measurable quantity that has agronomic relevance. It is referred to as composite because incorporates, and averages or aggregates, a plurality of growth rates taking place at the cellular level, even though they are not explicitly revealed in this function.
  • Said plurality of growth rates represents the cascades of numerous enzymatic biosynthetic reactions occurring in millisecond time scale or sub millisecond.
  • the combination of these cascaded (parallel and sequential) activities aggregates and yields the composite growth function, that is observable in seconds, minutes, hours and year time scales.
  • the composite growth functions of Eq. (8) may slow down and resume acceleration in periodic growth spurts, repeating nearly the same exponential behavior of Eq. (8).
  • the derivative dG BM (t)ldt of the composite function exhibits periodic peaks and valleys. Such behavior is normal in perennial trees which stop growing in the fall and resume in the spring.
  • spurts are also result from ratooning or pruning of certain trees such as sugar cane, moringa tree, and the like, and pinching off selectively shoots in order to spur the growth of branches.
  • the organisms described by the composite growth functions are relevant and included in many aspects of the present invention. They include natural or synthetic organisms whose genotype and phenotypes are altered by recombinant bioengineering practices, well known in the art, in order to perform specific tailored functions and or deliver substances of commercial interests. These recombinant organisms of various sizes include: unicellular, multi-cellular, micro-organism and macro -organisms.
  • r sth may range from hours, as in mass doubling time of algae, 6 weeks for Arabidopsis thaliana, or in the range or 10-20 weeks in many flowering plants of agronomic value.
  • the short doubling time of algae and other phototrophic organisms such as wolffia, and, lemna (duckweed), have biofuel agronomic values.
  • Eq. (5 a) becomes: Y ⁇ [G MB ( ⁇ )/ year] . This outdoor cultivation causes a loss of macroscopic temporal efficiency of a factor 3.
  • G MB ( ⁇ ) to vanish. This level of detail, revealed formally for the first time, will directly provide the capacity to engineer organisms, and growth systems for profitability assurance according to AgriPAL, Eq. (1).
  • the microscopic physiological efficiency is the product of a plurality of
  • S ⁇ S each of which describes, sequential and parallel events involved in the growth of the organism, including: photon capture, electron excitations, charge transport, electrochemical reactions, enzymatic bio-synthetic reactions involving enzymes, and cofactors, PSI, PSII, Rubisco, and other enzymes, and such intermediates as ATP, ADP, NADP+, and NADPH.
  • the macroscopic efficiency deals with the macroscopic growth aspects of one or more whole organisms and involves temporal scale in the range of seconds to days and spatial scale in the range of centimeters to hectares.
  • the quantity of iron available and absorbed a the organism is less than optimum, it will lead to S Fe ⁇ a Fe (oo) / ⁇ ftmax (oo) ⁇ 1 .
  • r Fe ( ⁇ ) is decreased below a threshold value, the organism will not survive, as it will be unable to carry out vital photo synthetic functions. The same outcome will result pertaining to deficiencies of the other substrates.
  • FIGS. 2A-2C present experimental measurement of photosynthesis, C0 2 assimilation of lettuce and strawberry cultivars as a function of light intensity, PAR, for different C0 2 input levels ranging from 200 ppm to 500 ppm, and 80% relative humidity. It was carried out using LI- COR System 6400xt instrument. In this experiment we increased the levels to 500 ppm higher than the average ambient level of 390 ppm. Other experiments have shown that much higher levels (>10,000 ppm) of C0 2 levels have been assimilated by algae species.
  • Similar gain factors can be realized by the optimization of the other substrates and environmental and other relevant photo synthetic parameters. This is one of the key aspects of the present invention in connection with indoor sun-less, and soil-less farming. More specifically the realization of gain factors that enter into AgriPAL Eqs. (6) (6a), (6b) that ensure profitability for staple commodities such as food and biofuel.
  • an overdose above an optimum value of a certain trace element may be toxic, or may be antagonistic to the uptake of other elements.
  • Below the minimum value of a certain component growth may either be prevented, or substantially reduced.
  • Above the maximum value may limit growth to a maximum, saturating or asymptotic value, or may be considered a toxic overdose that has adverse effect on the viability of the whole plant.
  • the absence of any key members means death, the presence of only a fraction of the optimum level means less than optimum yield, longer maturity time, stunted growth, etc.
  • Eq. (4a) separates the set S into related groups.
  • the following is a non limiting exemplary grouping scheme.
  • Other schemes may prove advantageous and may incorporate other components physiological and or physical parameters known to influence growth and yield. Few examples have been given to illustrate the roles of certain parameters; leaving out of the discussion other parameters should not limit the premises based on which the inventive embodiments are built.
  • the following grouping schemes are set forth:
  • S m S C0 ⁇ S H ⁇ 0 S 0 ⁇ : The main ingredients for building organism biomass: carbon dioxide, C0 2
  • S j S N S P S K : The primary nutrients made are of nitrogen, phosphors and potassium compounds (generalized as NPK). They are responsible for life giving bio-molecules, including: amino acids, DNA, RNA, ATP, ADP, NADP, polypeptides, phospholipids among others.
  • S n S s S Ca S Mg S Mn S Cu : These are the secondary nutrients, Ca, Mg, S, and the trace micronutrients, B, CI, Cu, Fe, Mn, Mo, Zn, among others, that are required in parts per million quantities, PPM. They are essential in spite of their relatively small (trace) quantities for the construction of key enzymes responsible for the regulation of growth, reproduction, signaling, timing, and storage. 10
  • S Br This efficiency component pertains to the genotype and the traits (phenotype) of the organism.
  • S Br is constrained by the local geography that is characterized by specific resource availability including: latitude, temperature, water, intensity of solar illumination, temporal availability of illumination (day lengths, season, ) , salinity, pH, and the local specific trace quantities of mineral. Certain locations are suitable for the high yield growth of specific cultivars while they cannot support others.
  • breeding is an expensive enterprise that is constrained to produce seeds of cultivars that can maximize their growth in the maximum geographical locations as possible, to ensure profitability of the breeding enterprise. It is costly custom breed a plurality of cultivars optimized to cover many small geographical regions. The consequence of this, is the breeding of cultivars with a compromised set of traits, in other words, the efficiency S Br is less than ideal.
  • One key aspect of the present invention is the decoupling of indoor faming from the conventional soil constraints, which we also refer to as SanSSoil farming. More specifically, the present invention enables the elimination of the constraints of breeding cultivar for different
  • One aspect of the present invention is to use a combination of foliar feeding and root feeding in parallel or sequentially to beneficially enhance the uptake of nutrients.
  • Another aspect of the invention is to sequentially pulsing groups of nutrients, i.e., applying a first short duration burst of a first group of nutrients, followed by a second short duration burst of a second group of nutrients, and the sequence is repeated as needed.
  • S env S sml S pH S T S weather S pest :
  • the efficiency components combine the effects of the environments on the organism health and agronomic profitability. This is one key aspect of the reliance on the zero cost of solar energy.
  • One of its main constraints is the requirement of cultivating outdoors on large 2D areas subjected to many adverse environmental impacts.
  • the soil serves many purposes including: mechanical support of the root, nitrogen fixing, supplying water and oxygen, supplies minerals that affect the pH.
  • the spectral efficiency S A is approximately 0.487, which represents the energy portion
  • the value of S approaches -0.5.
  • the enclosed indoor farming enables all the light to remain in the system by means of recycling (reflecting) from one organism to another. This is made possible by means of ensuring that light is absorbed within the system the components of which are made substantially non absorbing. In this case S may approach 1, thereby garnering a relative gain in efficiency of a factor of ⁇ 2.
  • the Microscopic Temporal Efficiency: S t In formulating the new PGM, Applicant discovered the microscopic temporal factor S t in the millisecond time scale, that represents the temporal mismatch between the enzymatic kinetics of Photo System II, and Photo System I , the fast light reaction, on the one hand, and the slow enzymatic Calvin reaction (dark reaction) responsible for assimilating C02 and producing glucose. Applicant discovered that this temporal mismatches factor is between 5 and 10 that previously had been unaccounted for as photosynthetic loss. This temporal loss factor ⁇ is identified, without being limited by theory, as the ratio S t « - ⁇ - « 0.2 - 0.1. This has been measured experimentally by Applicant by means on
  • inventive pulse light photosynthesis experiments that varied the pulsed light frequency from 10 Hz to 500 Hz, and pulse duty cycles from 100% (CW) down to 0.1% . These experiments are discussed below, with the aid of FIGS. 2E-2H.
  • FIGS. 2 A to 2H provide exemplary experimental illustrations of the ability to control the growth and gain parameters of various species obtained by Applicant.
  • Li-COR 7400XT photosynthetic instrument system has been used to determine the photosynthetic responses to various parameters including: temperature, humidity, C02, oxygen, light intensity (PAR), pulsed illumination at various frequencies, and duty cycles.
  • FIGS. 2A-2C measures the responses of two lettuce cultivars and strawberry, as light intensity and C02 levels are varied. This confirms the well known saturation levels that are determined and limited by the microscopic cellular enzymatic biochemical reactions discussed above.
  • FIG. 2D illustrates the fine temperature control available to indoor farming.
  • the graph shows the measurable difference in response to a 2 degrees temperature change. This validates the ability to hold the temperature fixed at a value that achieves maximum productivity, and gain factor for particular specie.
  • FIGS. 2E-2H is experimental illustrations and validation of temporal control according to the present invention.
  • FIG. 2E shows the response of a rose to applied pulsed illumination of LED at 860 nm, 50% duty cycle, as the period is varied from is varied from 5 millisecond to 200 millisecond. The response drops off from 6 to 3 at 100 ms (-10 Hz) which reveals the speed of the Calvin, dark reaction. This behavior is analogous to the cut-off frequency of high pass filters in we known in the electronics circuits art.
  • the plant behaves as a low pass filter, giving a photosynthesis response only below frequencies in range of 200-300 Hz.
  • the LED source at 860 nm is designed to deliver a train of high intensity light pulses of width r pulse and period ⁇ riod allowing the duty cycle in percent: dc ⁇ [i00(r pulse I r period )] to vary from 100% to 0.1 %.
  • FIG. 2F is an exemplary graph of Winter Destiny Lettuce photosynthesis response to duty cycle fro defect frequencies (1/ ⁇ riod ).
  • this loss is reversed as g t ⁇ 5, as can be measured from the slope as a means for controlling the temporal parameters of the light source.
  • This experiment also enables the measurement of the low pass cut off frequency and the speed limits of the light harvesting systems PS I & PS II. Note also that the gain is reduced as the frequency is decreased, showing the speed limit of the Calvin dark reaction of C02 assimilation.
  • the frequency is kept fixed at 200 Hz, and the duty cycle is varied for 5 lettuce varieties, indicating the same general behavior and showing temporal gain factors g t ranging from ⁇ 4 to 5.
  • the lettuce variety Paris revealed a gain of ⁇ 9 is possible.
  • This temporal behavior, trait has so far been repeated in all species tested, strawberry, broccoli, geranium, giving gains g t ranging from 3 to almost 10.
  • These gains are related to the speed mismatch between light reaction and the dark reaction and they are correlated to the ratio ij dark I ⁇ ⁇ ⁇ ) , and it the measure of efficiency losses which prior art could not account as discussed above.
  • Example 3 combining the above options 1 and 2 to achieve gains ranging from 10 to 1000. If solar gain is also added in the case, gains exceeding several 1000 will be possible.
  • Equation (4b) The microscopic, physiological yield components Eq. (4a) described in detail above reveals efficiency components, and parameters of gain and loss that has not been previously and transparently investigated. Equation (4b) describes additional macroscopic components, affecting the overall yield, that also had not previously been explicitly identified or described by plant scientists and agronomists. Their relevance is related to the economic viability and profitability according to AgriPAL. This may be unintentional omission for outdoor soil-based, sun based farming, because the growers and agronomist have had no or limited control over the growth condition as a result of their reliance of solar energy at zero cost.
  • the microscopic temporal efficiency ⁇ is the embodiment of the enzymatic kinetic speed of responses of various reactions that take place in millisecond time scale.
  • the macroscopic temporal efficiency, ⁇ ⁇ involves the life cycle time trajectory, (seed to harvest time r sth ) of the organism as a whole.
  • the germination, vegetative growth (exponential), flowering, pollination, fertilization, and fruit (seed) ripening all take place in a time scale of weeks and months.
  • the model plant Arabidopsis Thaliana needs about 6 weeks, while soybean, wheat and rice need 14 to 20 weeks.
  • One aspect of the present invention is teaching systems and methods that substantially regain the temporal efficiency lost outdoor environments for growing staple food, by using, instead, inventive architectures for indoor environment agriculture endows with the capability to enable energy efficiency ⁇ ⁇ to increase by factors ranging from 5x to 50x or even higher. This will allow the number of crops harvested per year to be ⁇ / ⁇ ( > 3 , which is the increase of annual yield per hectare.
  • Yet another aspect of the present invention is allowing the possibility of increasing the temporal efficiency by means compressing r sth by another factor of n t .
  • This temporal efficiency enhancement according to some aspects of the invention is in the range of 3-10, and more preferably from 3-20, and even more preferably from 20 to 50. Yet in other embodiments, the enhancement will exceed 50.
  • This macroscopic temporal enhancement in addition to other efficiency increases garnered from the components of, ⁇ j) micro , according to embodiments in the present invention have a multiplicative factor to give a large overall energy efficiency enhancement, rf E g ] E in excess of 50 time or even in excess of 100. It is these composite enhancements that enable the indoor farming of staple foods and other foods profitably. The ability to profitably cultivate and harvest many foods according to the profitability assurance, AgriPAL described in Eq. (1) can be shown not possible using prior art indoor farming.
  • Another aspect of the present invention is the teaching of an inventive three dimensional agriculture, multi-layer or multi-level farming, that increases spatial utilization efficiency by at least a factor of 10. By further increasing the number of vertical layers to about 100, the volumetric yield is increased by this number.
  • an inventive integrally made plant growing module or an integrally made plant growing element, or growing structure, a plurality of which are assembled into a three dimensional growing structures that feature ultra-space compactness, spatial compression, as manifested by the growing organisms sharing all the space and nutrients in unique manners.
  • AgriPAL has also been the catalysis behind the ability to make sun-less, soilless indoor farming viability for staple crops. Much higher profit margins can also be achieved for the production of non staple crops, by requiring the need for an indoor economic viability index: EVI e ⁇ rf E ⁇ g e J E which is the object of many embodiments of this inventions and related copending applications.
  • the transparency of the energy conversion efficiency components gained from the PGM enabled the realization of several gain components EVV ⁇ rf E ⁇ g ] E that satisfies AgriPAL thus:
  • ge g G , (G sp G t G f )(Yl gl )
  • One aspect of the present invention is an integrally formed growing element called SansSoil Growing Element, SGE. It is self-sufficient in the sense that it integrates many essential functions for growth in the smallest space and a lowest cost.
  • One distinguishing feature is the direct delivery of nutrients to the plant root from top down, instead of spaying the root from the bottom up.
  • the integral multifunction constructs of the SGE's enable their connection into strings and 3D network of strings that will save space and resources by sharing resources.
  • SGE SGE and their interconnection into networks of stings is the main object of the present invention.
  • these SGEs are interconnected in a manner that permits continuous flow agriculture.
  • the network of strings, forming multi-layer 3D systems is further distinguished from prior art by the inventive permeability feature of said multi-layers.
  • Layer permeability is defined as the ability to pass through to neighboring layers, light (transparency) and nutrients, received from other neighboring layers.
  • the shoots and roots of one layer may pass through neighboring layers. This enables the roots of one layer to share the space of the shoots of a neighboring layer below it.
  • the end result is high utilization efficiency of the vertical space by compressing the interlayer spacing needed.
  • the light transparency feature reduces the number of artificial illumination sources as well as the energy consumption.
  • AgriPAL enables an enterprise to predict profitability of plant growing systems, to prices, and to identify efficiency bottlenecks.
  • EVI economic viability index
  • EVI Plant Growth Model
  • AgriPAL AgriPAL
  • space utilization efficiencies which include three dimensional, 3D, soil-less (SanSSoil) plant growing structures and subsystems to sustain growth. More specifically, the aspects that reduce the cost of said structures and subsystems which lead to the minimization of the parameter f in Eq. (1). Even more specifically, the increase of g ⁇ E which is a function of the n, the number of vertical layers in 3D farming systems wherein the yield is measured in units of ton/hectare-meter, or ton/m3, or kg/m3.
  • plants are grown in 3D space that is limitless. More specifically, 3D space including, growing plants in 3D edifices, structures, or towers of heights, ranging from 10 meter to 100 meters, and even more preferably tower heights beyond 100 meter perhaps approaching 500 meter or even 1000 meter. Building having heights exceeding 500 m already exist. It is also known that making wind turbine tower as high 150 m is economically feasible.
  • systems and methods are disclosed that enable the increase in productivity using the system of Traveling Seed Amplifier, TSA, to enable continuous flow farming or production of material products, MP, including PMP, and CMP, synchronous planting and harvesting, and novel systems and methods to compress vertical space and time required for MP growth.
  • FIG. 3 A is an exemplary depiction of an indoor SansSoil farming system 100, comprising a SansSoil sheltered and protected controlled environment 101 and a control subsystem 102.
  • the SansSoil sheltered and protected controlled environment 101 is designed to be substantially impermeable to pests, and undesired gases, liquids, particulates, and other foreign objects.
  • Preferably said protected environment is well insulated and protected from outside temperature swings in order to maintain a desired temperature that is most suitable for growth and results in maximum productivity.
  • solar radiation may augment artificial light for photosynthetic growth.
  • the SansSoil environment 101 may be equipped with filters to filter out unwanted solar wavelengths including ultra-violet, infra-red and certain visible wavelengths.
  • the hybrid growth method based on the combination of artificial lighting, preferably LED, with selected solar wavelengths, will enable the maximization of g e g so i ar , viability index and the profit margins established through meeting the AgriPAL conditions.
  • the SansSoil environment also comprises structures for handling, planting seed/seedling in the input port, 105, also referred in certain embodiments to as the planting port.
  • the mature plant product is harvested at the output port, the harvesting port 104.
  • Said structures are preferably designed to incorporate appropriate sealing structures such as load locks in order to maintain sterile or near sterile conditions. Structures to achieve impermeability and sterility of SansSoil edifices are well known to persons skilled in the art.
  • the SansSoil environment 101 houses a plurality of SansSoil material product, MP, growth layers 103 disposed in a three dimensional space.
  • the SansSoil MP layers are made from structures and materials that are optically transparent, thereby enabling the layers to share and recycle unabsorbed light, and thus increasing the light energy utilization efficiency.
  • control subsystem 102 is programmed to control all aspects of growth physiology to
  • Each gain parameter in the portfolio has an optimum range that gives the maximum value. This is adjusted by the subsystem 102 for each species. The upper and lower limits of this range are determined experimentally in optimized environmental parameters.
  • a group comprising more than one interacting parameters can be adjusted and optimized together. For example, adjusting the carbon dioxide to an optimum value limited by the dark reaction enzyme density requires adjusting the light level until it is limited by the light reaction enzyme density. The steps of optimization are aided by appropriate sensors which communicate with the controller values that require adjustments.
  • Each layer 103 within the SansSoil environment 101 is so designed to sustain the growth of plants or organisms in integrally made SansSoil growth elements (modules), SGE 1, described further in FIGS 3B-3K, and FIGS. 4A-4P.
  • the layers 103 and the plurality of SGE's are spaced in such a manner that optimizes the space utilization efficiency G sp .
  • Each SGE 1 comprises integrally made structure la, lb which houses the plant 2, the shoot 2s, and the root 2r, and connected to a nutrient sources 3, 3a. The nutrients drip or spray downward on the root in the cup like substructure.
  • One key aspect of the present invention is to combine this method of feeding, with foliar feeding, well known in the art. This is accomplished by means of fogging subsystem (or mist), which preferably supplies micron scale fluid particles (droplets) that are absorbed directly by the plant leaves, by-passing root uptake.
  • Each SGE 1, optionally and integrally comprises a light source 4, and a sensor 5.
  • This inventive feature is unique to indoor farming, according to the present invention, because it affords a new degree of freedom for the subsystem 102 to control the components of gain factor g e , through optimization of the operating range of each component. This is especially advantageous when two sets of nutrients are antagonistic to each other, competing to prevent the optimum pH to establish for maximum beneficial uptake.
  • FIG. 3B shows that in each of layers 103a, 103b, and 103b, the SGE's (FIG. 2C) are connected in strings 106, that are connected to nutrients sources delivered to each SGE site.
  • the SGE repeat at period px, 107a
  • the strings repeat in the second coordinate, y, at a period py, 107b.
  • the layers repeat at period pz, 107c.
  • the dashed lines 108 depict columns of SGEs in there respective layers.
  • the total number of plants in the 3D system, N 3D (N x p x )(N y p y )(N z p z ) , determines the overall 3D productivity of the system 100.
  • the illumination sources lh, lj and auxiliary sensors, lg, or other resource are disposed in any orientation relative to the three spatial coordinates, FIGS 3C-3E.
  • FIG. 3F a plurality of SGEs are connected as a linear string 1 11 a, which is connected to one or more sources 3.
  • the connection structures are so designed to deliver, with high conductivity, nutrients to each site 1.
  • these structures are designed for quick connection to the SGE, enabling rapid, inexpensive and automated means to form a long string.
  • These structures also have the strength to support the weight of the plants in the string.
  • FIG. 3G shows a cross section of a typical string.
  • FIG. 3H many strings 1 11a, 111b, are placed in parallel to form a layerl 03.
  • the cross section FIG. 31 illustrates an embodiment of a permeability feature of the present invention, namely, the empty space between strings. This empty space enables the sharing of nutrients and light, that pass through between the strings and between the layers. This permeability also includes the ability of shoots and roots to overlap and share the same space.
  • FIGS. 3J-3K The advantages of the string interconnections is further highlighted in FIGS. 3J-3K wherein two layers 103a, 103b disposed vertically, each comprise a plurality of strings.
  • the space between two layers is pz. It will be show later in a different embodiment that the period pz, interlayer space can be made to vary, plant manually or automatically, depending on the plant age and accordingly height.
  • the plant age or the growing material product age is defined as the time that has elapsed from an embryonic time, an initial time, corresponding to an initial material mass size.
  • This initial material may be seed, seedling, embryo, initial cell culture or initial microorganism microorganism culture.
  • the initial age of material product, MP is the initial time ⁇ ⁇ , having an initial mass, m i , which grows to a final age, final harvesting time, ⁇ f , having an amplified final mass,
  • integral multifunction is defined as a structure that comprises at least two substructures integrally made, substantially permanently attached, so as to carry out at least two functions. These at least two functions are chosen from the group consisting of mechanical support, growth sustenance, germination, self-supplying of nutrients, self-supplying of light, a sensing environment, and communication of nutrients to nearest neighbor.
  • the SGE in FIG. 4A comprises growth compartment or substructure la which mechanically and physiologically supports the growth of the root 2r and the shoot 2s to maturity.
  • the substructure l a is integrally attached to a connecting conduit lb, that is in fluid communication with growth substructure l a, through an orifice or an opening l c. Fluid Id, flows through said orifice lc, supplying a stream If to the root.
  • Conduit lb may have any cross section as shown in FIG. 4B.
  • Conduit lb is removably attached to at least one source 3.
  • Said attachment is preferably quick connect disconnect type with sealing function to prevent leakage, le.
  • the source 3 provides essential resources and ingredients to optimally sustain plant growth.
  • Said resources comprise at lease water and nutrients, but may also conduct and deliver light by means of total internal reflection mechanisms, well known in the fiber optic art and the back-light sources well know in the liquid crystal display art.
  • the conduit may conduct electrical signals or power from sensors and to local LEDs integrated directly into the conduit lb.
  • Conduit lb according to FIGS. 4C-4D serves to connect plural SGEs to form strings as described above, FIGS. 3F-3K, and to pass resources 3a from one SGE to another.
  • Said resources include fluids, conducting signals from sensors 5, 5a, and energizing LEDs 4, to provide illumination 4b to local plants.
  • the SGE also comprises a seed support structure lm, which functions to mechanically support the seed 2 (FIG. 4E), and to provide the optimal environment for high germination rate.
  • strings can be constructed and arranged so as to hang from top to bottom, 11, 12, with the SGEs oriented in the desired directions determined by the light as shown in FIGS. 4K-4M.
  • Integrally made multi-function self-sufficient SGE may be attached to feed structure, or string interconnection sutures, 3, in a plurality of desired configurations, 20a-20e, shown in FIG. 4P, depending on the plant species and system design requirements. Persons skilled in the art may produce other configurations, without departing from the SGE network interconnectivity described and claimed in the present application.
  • Layers 200a and 200b comprise strings of SGEs 1, the bottom of each share the same space 201. Conveniently, the space 201 shared by the roots becomes the conduit to supply the nutrients 202 in the direction of the arrow.
  • the string interconnections further provide for energy delivery to the LEDs to supply the illumination 203a, 203b.
  • FIGS. 6A-6E illustrate non liming examples of systems enclosures geometrical configuration, 100, 100b in relation to the feed subsystems, 112, 113, 114, 115, 116 delivering streams 117 fluid and light from all sides and optionally from the top and bottom.
  • FIGS. 6C-6E shows stackable self sufficient configurations of complete system that comprise automated means to input (load) seeds and seedlings and harvesting the final product in a totally aspect manner sees or seedling trays.
  • Said means may further comprise load-locks chambers as the interface between system 100 and the outside world, thereby ensuring aseptic loading and unloading.
  • the preferred embodiments comprise means to maximize resource utilization efficiencies. This is accomplished by means of sharing these resources which include: illumination sources; nutrient delivery subsystems, supporting structures, and space.
  • the means for sharing which are described in FIGS. 7A-7D result in the reduction of the system fixed costs, f, as well as the variable consumable costs, v, thereby ensuring maximum profitability, according to AgriPAL Eq. (1) above.
  • the definition of permeability is the ability of a layer comprising at least one string of SGEs to pass resources from a first group of neighboring permeable layers, to a second group of neighboring permeable layers.
  • the first and or the second group may comprise resource delivery sources.
  • the total number of vertically disposed layers ranges from 2 to 10, and more preferably from 10 to 100 and even more preferably in excess of 100 layers.
  • the permeability feature of the present invention enables the sharing of resources, including water, nutrient, illumination, heating and cooling and other sharable resources.
  • the sharing of said resources enables their efficient, use thereby minimizing the ultimate product cost.
  • the 3D yield or 3D productivity is measured in units of weight divided by volume and units of time. Therefore, the permeable means for sharing resources are designed to produce the maximum product weight in the most compact 3D space in the shortest time. These means are described in conjunction with FIGS. 7A-7D.
  • System 300 comprises at least layers 301 , 302 which are built by stringing a plurality of SGEs 1, as described in more details above and with respect to FIGS. 3F-3K.
  • Layers 301, 302, and the connecting structures, 301 a- 301c, and , 302a-302c as well as SGE structures, are made substantially optically transparent so as to allow light rays 305a-305d from sources (not shown) to pass through layers 301, 302 to illuminate the plant shoots 303s, 304s of neighboring layers.
  • the optical transparency of layer structure is made possible by use of transparent materials including but not limited to glass, polycarbonate, polyethylene, polypropylene and polystyrene.
  • This means of achieving of light permeability enables multi-layers to share at least one light source growing plants, thereby realizing the maximum efficiency of the light source.
  • seedlings are small and are separated by wide lateral and vertical spaces. It takes months before the space between them is filled. During this time the light that is not absorbed by one layer, passes through to be absorbed by neighboring layers. The end result is that only a few light sources are used to illuminate a large number of layers. This immediately results in the reduction of initial capital cost of the light sources. For example, a 100 layer (permeable) system may be served by only one planar light source located on top of the system. By adding reflecting system walls, wasted light is minimized.
  • prior art 3D farming system in FIG. 1C contemplates using one set of light sources for each layer, clearly revealing inefficiencies of these systems. It further validates the significance of the permeable features in certain embodiments of the present invention.
  • the permeable layers In addition to minimizing the initial fixed cost of light sources, the permeable layers also use the consumable light energy efficiently, lowering the variable cost of production. Any light that is not absorbed by a permeable layer passes through to adjacent layers to be consumed by plants in these layers. In conventional teachings, the light energy that is not absorbed by plants is irretrievably lost as a wasted resource.
  • FIGS. 7B-7C another type inventive permeability feature is described. It pertains to the roots 303r, 304r, and shoots 303s, 304s (stems, branches, leaves) of plants in one layer penetrating (sharing) the space of roots and shoots of plants in adjacent layers 306, 307. This space sharing achieves an unprecedented vertical compression, reducing the vertical height d, 308, 308a, many times. The absence of this space sharing would have required maximum height for roots which added to the maximum height of shoots, and the system would be vertically less compact.
  • FIG. 7D illustrates yet another type of permeability, which is the ability of one layer to pass through unabsorbed nutrients to adjacent layers.
  • Nutrients essential for sustaining optimum growth of plants are provided by sources (not shown) in the space 309 occupied by at least the multi-layers 301, 302.
  • Exemplary sources include fogging system, spraying system, and dripping systems which intermittently fill the space 309 with nutrients. These nutrients are delivered to the plants by means of foliar feeding or root feeding.
  • FIGS. 3F-3K show that string of SGEs in each layer are spatially separated by empty spaces which allow the nutrients to pass from one layer to the next. This permeability also minimizes the number of feeding sources and their initial cost.
  • AgriPAL and PGM are used as guiding principles enabling the realization of the full potential of 3D SansSoil farming paradigm. Emphasis has been placed on the ability to control physiological and physical parameters. In further embodiments, herein, higher gain are achieved therefore enabiling higher efficiency, increased space utilization efficiencies, by means of vertical compression, layer permeability and by making ultra-compact layers comprising strings of networks of integrally made SGEs.
  • the teachings herein include three dimensional architectures that feature several examples of compactness and high space utilization efficiencies including: transparent layers 103 and SGE's 1 to recycle light to minimize wasted light, the overlap of root space and shoot space to minimize wasted space, and to provide more than one root and leaf feeding options.
  • bio-energy peanuts (diesel), sugar beat (ethanol), Russian dandelion (butanol), Algae- biofuel
  • TSA traveling seed amplifier
  • the TSA system, 400, in FIG. 8A, is a 3D SansSoil continuous flow farming system for the production of material products.
  • the TSA system may be designed to achieve gains, G sth having values in the ranges of 2-10, preferably 10-1000, more preferably 1000- 100,000, for cell cultures, and event more preferably 100,000 to 100 million.
  • the initial mass, m i may be one or more masses selected from the group consistinf of seeds, seedlings, plant cell culture, micro-organism culture, microalgae culture, bacteria culture, fungi culture, stem cuttings, root cuttings, leaf cuttings, and eye cuttings.
  • Said initial mass is planted in one or more SGEs, in one or more growth trays, wherein said SGEs are arranged one dimensional, two dimensional, and some cases 3 dimensional patterns, as in the cell culture trays 450 in FIG. 10A. These patterns may be regular periodic arrays, or other patterns advantageous for seed growth.
  • temporal compression factors N ranging from 10 to 1000 preferably from 100 to 10,000 and even more preferably exceeding 10,000, are provided, for instance, in the case of algae and other culture made products, CMP.
  • the high temporal compression factors have significant implications for growing food and energy. For example, if com cycle time r sth is 100 days, from seed to maturity, the 3D TSA system according to this invention, enables the planting and near synchronous harvesting of corn once per day or 10 times a day for compression range from 100 to 1000.
  • the layers N are disposed vertically, the third dimension, the volumetric productivity, and the 3D yield increase by N. This is saves arable land and enables food and biofuel to be planted and harvested daily, continuously or semi-continuously, without the concern that biofuel competing with food for 2D land and other resources.
  • the TSA system for continuous growth of material products, MP in FIG. 8A, comprises one or more towers, 401, 402, preferably in pairs. It may optionally comprise a single tower or a cluster of plurality of towers. It also comprises, housings 401a, 402a, an input, planning port, 404 an output harvesting port 405, a utility subsystem, 406, for resource delivery and system control (subsystem 102 in FIG. 3A), and a plurality of mobile layers 403a, 403b, traveling upward in tower 401 and downward in Tower 402.
  • the construction of the MP growth layers in towers 401, 402 incorporate the inventive features described above.
  • the 3D array compactness, and space compression means of interconnecting a plurality of SGEs into strings disposed in horizontal planes or vertical planes.
  • the overall system performance also benefits from the multifunction capabilities, discussed above, of each individual SGE.
  • the SGE may generally be used to amplify materials not only based on high plants, but also other materials including algae culture, and other cell cultures.
  • the SGE for these other material sometimes are referred to as reactor growth elements or bio-reactor growth elements.
  • at least one layer 403c comprising at least one initial mass material, at a first age, ⁇ ⁇ , is admitted by transport means described below, FIG. 9A, into at least one initial location input location or planting port 404 in a position 404a.
  • the initial mass material may be plant seed, seedling, or cell cultures which will be amplified.
  • the layer 403c is moved one layer position upward and concurrently all other layers in both towers shift to the next adjacent position, until the last position 405a in the second tower is refilled. This last position 405a, had just been vacated a short period earlier, ⁇ ⁇ by the harvesting operation of layer 403d at its second age ⁇ f at the harvesting port 405.
  • the synchronicity period ⁇ ⁇ is measured from: i)- the time of harvesting layer 403d; ii)- vacating the last position 405a; iii)- shifting all the layers to their adjacent positions; iv)-refilling position 405a; v)- vacating the first position 404a; and finally iv)- inserting layer 403c, in position 403a.
  • the degree of synchronicity is defined thus: d ⁇ ⁇ ⁇ lr h .
  • perfectly synchronous planting and harvesting is achieved in a design that achieves d « 0.
  • d may have values ranging from 0.001 to 0.1, or may approach 0.5.
  • the synchronicity is controlled by the system controller, or by manual operation. However, in other non-normal operations, d may exceed 0.5.
  • the preferred embodiment for layer transport mechanism further comprises a means for lateral transport of layer 403e, from position 404b in the first tower 401, to a second position 405b in the second tower 402.
  • a non liming example to implement the lateral transport means is an electromagnet that latches to layer 403 e, so that together they move laterally in a synchronized manner with the layer transport systems described in FIGS. 9A-9B. Once layer 403 e is in a predetermined position in tower 402, the electromagnet will unlatch, to enable layer 403 e in a condition move downward.
  • h h is the plant height at harvest time, before flowering for vegetable products, or after fruit, seed ripening.
  • C TSA ⁇ - ⁇ - is the vertical space compression which reduces the average interlayer spacing, h av .
  • Compression factors between 2 and 5 are possible even 5 to 10 in systems where plant strings are mobile in two spatial coordinates and the plant spacings in two directions are automatically adjustable according to plant age.
  • the interlayer/ ⁇ , 408a varies from the smallest height of the seed/seedling layer at position 404a, to the maximum height, h h , at position 405a. This results in the compressed average height h av .
  • the compression factor also incorporates the other space saving features discussed above, including: the permeability, the shoot and rood volume overlap, the ultra-compactness of SGE connected in networked of strings in layers 103, 403.
  • the two tower housings 401a, 402a instead of being separated with a space 407, they may have a single common housing. They optionally may be sheltered in yet a third housing which also shelters additional tower cluster, downstream processing equipment, and other facilities. In other options, when the TSA towers are housed in a larger enclosed protective environment, the housing structures 401 a, 402a, may be open to said larger protective environment, or may be eliminated altogether. Additionally, the tower housings may be substantially transparent, to optionally allow solar illumination, in addition to artificial lighting. They may also comprise variable transmission windows, retractable curtains comprising filters, absorbers, and reflectors.
  • the subsystem 406 controls all aspects of plant growth delivered by subsystem 102, as discussed above and illustrated in FIG. 3 A, in addition it controls additional functions of TSA system 400, including: vertical layer transport, lateral transport (no shown), tower rotation, planting and harvesting, and load lock control.
  • the TSA tower system 400 may be a member of tower clusters, each comprising a plurality of towers. It is contemplated that the subsystem 406 of each TSA tower communicates with a cluster master controller remotely, the latter, in turn, may communicate with yet another master controller located in a remote location. Persons familiar with the art of remote control can execute these tasks.
  • the towers can be rotated at an appropriate speed to track the sun and or to improve the illumination uniformity from the sun or an artificial lighting source;
  • the towers are equipped with sterility functions, to protect the plants from harmful pathogens and also to consumers from harmful pathogens. It is contemplated that isolation may be achieved by installing load locks in the planting and harvesting ports 404, 405.
  • Each load lock is a chamber comprising sealable doors that enable the sequential transfer of seed layers in (initial mass) in, and harvested products out. The seed layers are admitted through a first door that is in communication with the outside environment. This door is subsequently sealed, and the layers are sterilized in situ. Subsequently, a second door, which is in communication with the main TSA system housing, is opened, and the layer 403 c is transferred to its position 404a.
  • the next step is resealing the second door, making it ready for the next repeat cycle.
  • the operation of harvesting load lock chamber is the same except the steps are in reverse.
  • Aspects of the invention contemplate automated transfer of layers and trays from chambers 404, 405, or optionally semiautomatic or manual transfer.
  • human operators may be involved in the process of planting and harvesting inside the sterilization load lock chambers. In this case, sterilization methods for humans will be adopted as is well known in the sterilization art.
  • the inventive TSA daily, continuously, admits, plants seeds/seedlings and harvests synchronously products for immediate consumption by consumers or for downstream processing converting them into other forms of the products.
  • planting and synchronously harvesting [ intermittently] once every day or every 5 hours is referred to as continuous or semi-continuous because of the regularity [regular period] of the operations.
  • the daily harvesting in some cases several times a day, for very tall towers, takes place uninterruptedly, 24 hours a day all year around. Even though, there is a non zero time period between the synchronous planting and harvesting, the operation is 24/7 uninterrupted operation and on a time average basis, we use the term continuous relative to conventional farming wherein the period between planting and harvesting may be a year or longer.
  • Typical annual crops, soy bean, and cereals have intrinsic r sth in the range of 100-120 days, and
  • TSA 3D sansSoil farming architecture 100 m tower and C TSA -0.333. This is a non limiting example to illustrate the power of TSA 3D sansSoil farming architecture.
  • the antisense times varying according to species and growth conditions.
  • Another example related to algae culture for biofuel production, r sth ⁇ 0 days, and h h ⁇ 0.0 ⁇ m, will achieve a planting/harvesting time
  • FIG. 8B is an exemplary plant height growth trajectory curve and plant biomass growth trajectory described, respectively, by the following expressions: h(t) ⁇ h( ⁇ )( ⁇ - e ⁇ k '');M BM (t) ⁇ M( ⁇ )( ⁇ - e ⁇ k,t ) .
  • These functions illustrative and are not intended to limit the present invention. These functions also approximately describe the growth trajectory of other living cell cultures, microorganism, and the like. These functions may composites which comprise two or more growth phases of different growth rates.
  • soybean seeds would be planted daily at, and mature dry soybean pods are harvested synchronously (daily) at h l20 .
  • One seed layer goes up one position in the left TSA tower and mature harvested layer goes down in the right TSA tower. This is a daily amplification of the seed biomass.
  • N 1000 layers and beyond, then At will be less than 0.1 day.
  • At will be measured in minutes or even seconds.
  • FIG. 8D a segment 410a of the whole soybean growth trajectory 410 is shown on the left.
  • the segment 410a is magnified to show more details of the time period corresponding to heights from z 0 to h 20 , wherein said time period is divided into 20 intervals At .
  • layers 403 vertically located in their respective heights from z 0 to h 20 .
  • FIG. 8E is an illustration of linearization of the growth trajectory that aid in determining the number of layers and interlayer spacing for each of the 5 linearized segments 410a to 410e.
  • FIG. 8F in other aspects of the present invention, flexibility is allowed with regard to the locations of the planting and harvesting ports, 404a, 405 a in TSA system 400d, or 404b, 405b, 405c in system 400e.
  • the system may have more than one planting port or more than one harvesting port in locations determined by overall function of the system.
  • the system, 400f has growth layers 403 which may be disposed in the y-z spatial coordinates, i.e., vertical planes as shown in FIG. 8G.
  • the TSA transport system moves the layers horizontally with a constant velocity so as to adjust in real time the interlayer spacing 420a at the seedling stage to spacing 420b near maturity.
  • the hanging layers may also comprise a plurality of individual independently hanging strings, of SGEs, as shown in FIGS. 4L, 4N and 4P.
  • the spacings between these SGEs vary in the x direction from seedling to maturing spacing, thereby allowing yet a third TSA compression factor.
  • the overall TSA compression factors in at least two spatial coordinate directions can approach 10.
  • the TSA transport system comprises one or more screw rods (or auger-like helical rods) 412a, 412b, having a helical thread comprising one or more pitches, p 1 , p 2 , p 3 , p 4 , p 5 , p 6 ,
  • the screw rods are designed to have variable pitches, a plurality of pitches, the number of which is selected from the ranges 1-10; 10-20, 20-100.
  • temporal compression factors between 1 and 10, preferably 10 to 100, and even more preferably, 100-1000, and spatial compression factors, ranging from 1 to 10.
  • Compression factors of larger than 10 as also achievable, according to the present invention, by means of the cumulative effects of space saving from root-shoot overlap, from the compactness of the integral construction of SGEs, as discussed above, and the TSA automated variable interlayer spacing adjuster 411 in FIGS. 9A-9B.
  • the growth layers 403 generally comprise one or more trays (plurality of trays) 403t each comprises one or more SGEs, and a frame or a handle structure 403h that supports the trays.
  • One or more trays are removably attached to their respective handle structures. Even more preferably, in some embodiments, the trays are deposable, one time use.
  • Said one or more SGEs are in the form of at least one network of strings, and more preferably in the form of one dimensional or two dimensional arrays.
  • Each tray is in communication with fluid delivery and light delivery subsystems (not shown).
  • the handle structure 403h is in direct physical communication with the screw rods 412a, 412b at contact regions 416c, and 417c.
  • the interlayer spacings are maintained by the rod pitch associated with each tray vertical location and maintain spacings.
  • the tray and handle thicknesses may not have the same values. These thicknesses are chosen from these ranges: 10-100 micron, 100-1000 microns, 1 -10 mm, and 10-100 mm. While the periodic or non periodic spacings between SGEs are chosen from these ranges: 10-100 micron; 100-1000 microns, 1 -10 mm, 10-100 mm, and 100-1000 mm.
  • the thread-form of the screw rods are machined in such a way that the depth and the flank shapes of the thread can accommodate and hold the handle structures 403h of the growth layers and have the strength to accommodate the layer's load.
  • the spacing between the screw rods enables the growth layers to be held firmly yet with the ability to be easily removable, during the steps of planting and harvesting.
  • the screw rods 412a and 412b are coupled to a subsystem comprising at least one motor, at least of one set of chain belt- gear arrangement and supporting structures fixed to the mainframe housing.
  • the rods counter- rotate, 416, 417, cooperating synchronously to lift all the layers 403 upward or downward at the contact regions 416c, 417c.
  • the pitch variation as a function of height is determined by an algorithm which at least reflects the plant growth trajectory that is measured experimentally.
  • the number of screw rods needed to transport the growth layers varies from 1 to 10.
  • the hanging growth layers 403 are transported to the right by means of a single screw rod 412c, that is it rotates, it translates the layers linearly, while at the same time adjusts and maintains the correct interlayer spacings 420a, 420b, according to the age of the plants.
  • This single screw rod arrangement in addition to its simplicity, and low cost, it has a major additional advantage in that it does not need to support the weight of the hanging layers. It only needs to push to translate the layers after overcoming frictional forces.
  • variable pitch thread-form may be incorporated in the inner surface of a rotating cylindrical housing to enable the upward or downward motion of N layers.
  • Said N growth layers have areas or diameters designed to efficiently occupy the volume of the rotating cylindrical housing.
  • the incorporation of the thread-form may be accomplished by means of machining (or embossing) substantially the entire inner surface. To lower the cost, especially when the diameter exceeds 1 meter, it may also be accomplished by the partial machining (or embossing) of the inner surface.
  • the partial machined (embossed) area covered may be in the form of a plurality of axially oriented thread-form strips. The number of these strips may be in the range of 2 to 6 or 6-24 if the diameter is very large.
  • the length of the strip is approximately the length of the cylinder, and its width is a fraction ⁇ ⁇ ⁇ diameter . This fraction may be between 1/8 and 1/32, or may be smaller than 1/32, depending on the number of strips and the design of the layer structure.
  • variable pitch screw rod system is the most advantageous solution to the problem, of self-adjusting interlayer spacing as a function of growth, there are other mechanisms persons skilled in the art may conceive based on moving belts and chains. Applicant has discovered that the variable pitch rod mechanism features many more advantages including: high performance, compactness, low noise, low cost, flexibility, and scalability to very high tower heights.
  • TSA embodiments according to the present invention have been designed, built and evaluated for growing lettuce as a vehicle to validate its operability, and the key inventive functions that make the TSA unique.
  • FIGS. 9C-9E TSE system A system 400a has a base of 1 m 2 and a height of 1 meter, designed to accommodate 20 growth layers. Lettuce was chosen as an example that represents food products, and when genetically transformed, it represents medicinal products, vaccines, and antibiotics.
  • FIG. 9C the main frame extruded aluminum housing structure, 418, is shown, to which four screw rods, 412c, 412d, 412e, are attached. Also shown are sprocket gears, a chain belt and a manually rotated wheel. The motor driving this transport mechanism is on top in FIG.9D.
  • Aluminum frames or handles 403h are shown supporting transparent growing trays 4031. The frame, 403h along with 4 trays 403t constitute a complete layer 403.
  • FIG. 9E shows two perspectives views of a substantially complete TSA system, 400c, comprising: the housing 418, the planting port 404, the harvesting port 405, plurality of growth layers 403 populated with lettuce at ages corresponding their height, permeable to light, nutrient, and roots and shoots of neighboring layers. As can be seen, the interlayer spacing varies from very small at the bottom, 2.5 cm, to 25 cm at the harvesting port, reflecting the ages of lettuce.
  • the system also comprises a master controller for controlling the motion of the layers, the pulsed LED lighting, water, nutrient delivery, pH, temperature, and relative humidity, as described herein.
  • FIG. 9F illustrates system 400d which is a scaled-up embodiment of system 400c, in FIG.
  • the transparent trays 403 are uniquely designed in a hexagonal SGE array configuration capable of many functions, including, germination, amplification, mobility, interlayer spacing adjustment, and water and nutrient delivery with virtually no plumbing.
  • the transparent hexagonal arrays are visible in the trays of FIGS. 9C-9D.
  • the hexagonal array of a specific layer is rotated relative to its neighboring layers, in the manner to allow said specific layer to receive water and nutrient of a layer on top, delivers water and nutrients to its own plants, and relay the rest to the bottom neighboring layers. This relaying function enables the entire layer to receive an appropriate nutrient level needed to sustain growth.
  • the TSA systems along with the TSA transport mechanisms described above, FIGS. 9A-9B and systems shown in FIGS. 9C-9F for growing lettuce may also be used for cell culture (suspended of immobilized) for the production of MP, including plant made products, PMP, and culture-made-products, CMP. They may also be used for the production of other materials that rely on catalytic or enzymatic conversion reactions of one or more substrates.
  • the latter reaction processes are analogues to cell culture methods, except that the catalysts are made of non-living matter, including molecular sieve, zeolite families, metals, and other particles comprising acid or basic catalytic sites. All of these methods for the production of matter benefit from the inventive features of TSA and TSA transport mechanism.
  • the culture methods may include prokaryote, eukaryote cells, microorganisms, algae, cyano-bacteria, other bacteria and fungi, and a variety living organisms generally referred to as autotroph, photoautotroph, heterotroph, or mixotroph. These cells represent naturally evolved species or genetically transformed by well known recombinant DNA engineering methods. These methods may include transient (plastids) or nuclear genetic transformation. In these cases, the trays are specifically designed to comprise one dimensional or two dimensional SGE arrays 400 in the form of micro-wells or troughs, 451 a, 451b, 451 c, 45 Id, 45 le and 45 If, as shown in FIGS. 10A-10B.
  • Each composite TSA mobile layer 403x comprising a handle structure, 403h, and one or more trays 451.
  • a plurality of TSA composite mobile layers 403x are transported according to the present invention by means of the TSA transport mechanism 411, FIGS. 9A-9B.
  • Each of the plurality of trays 451, in the composite layer is designed to have a specific structural strength that enables the stacking of a large number of trays, so that they can move as one unit, a composite layer, and to support the total load including that of the culture mass 452.
  • the trays 541 are designed to comprise self-alignment features relative to the neighboring layers and to maintain inter-tray spacing s c .
  • the trays 451 are so designed as to facilitate the filling, or emptying of the culture and culture media, in a single operation, of all the micro-wells 451a in a composite layer 403x.
  • the single filling operating enables the automatic adjustment of the micro-well levels 454 to achieve an identical full height d c .
  • This single operation filling is accomplished by means of perforations 453 in all the trays.
  • the culture growth element arrays of the trays have periods in two dimensions p a , nd p a , which may be in the ranges of 10 to 100 microns, 100 to 1000 microns, 1000 to 100,000.
  • ultra-high surface to volume ratio of the micro-wells is achieved, to enable fastest gas exchange as illustrated by the arrows 456 in FIG. 10B which represent the diffusion of metabolite gases in and out, including 02, C02, alcohols, and other volatile primary or secondary metabolites, depending aerobic, anaerobic or fermentation metabolism of the growing cells. It is desirable to maximize the gas exchange speed for metabolism and growth conditions. This is a accomplished by means of decreasing diffusion lengths of metabolites and increasing the diffusion speeds, such outcomes are
  • d c values are chosen from the ranges: 10 micron to 100 microns or 100 micron to 5000 microns. The values are optimized based on well known behavior of dissolutions of metabolites in culture media, temperatures, and pressures.
  • TSA bioreactor exemplified by the composite layer 403x constructions as in FIG. 10A-10B makes a large volume system production with maximum efficiency, productivity, yield flexibility and scalability at the lowest cost.
  • One of the key to maximizing productivity (volume to volume) is maximizing the culture density.
  • the present invention ensures that, by achieving a large surface to volume ratio with ultra-shallow depth d c , and the immediate access of each cell to the ambient environment for nutrients, and for optimum gas exchanges.
  • Productivities well in excess of 100 niL/L and even more than 500 mL/L are possible.
  • the culture cells may be immobilized in trays and in mobile layers which can be intergraded in TSA systems that benefit form the high density and productivity features.
  • the culture array elements, 451a, 451b, 451c, 45 Id, 45 le and 45 may be designed to have diverse periodic array geometrical arrangements, configurations and micro-well trough shapes (physical profiles), depending on the benefits that accrues for a specific application growth conditions and growth environment.
  • One preferred thin walled trough is the concave shape 451 c designed from a material and a surface coating 455a that prevents the cell culture and cell culture medium 452a from sticking.
  • This phenomenon is referred to as fouling in prior art bioreactors, especially, algae bioreactors. In these reactors, fouling is considered to be one of major hurdle preventing large scale algae from reaching profitability, as tested by our AgriPAL condition.
  • This non-stick feature according to the present invention enables the filling and emptying of the wells with minimum friction, so that the fluid flows or glides effortlessly and enables the reuse of trays very large number growth cycles ranging from 100 to 1000 or from 1000 to 10,000 and more preferably approaching 100,000 cycles.
  • SHC super-hydrophobic coatings
  • SHC super-hydrophobic coatings
  • the SHC is characterized by a fluid 452a having very large contact angle in the range of 150° and 180°. This enables the culture medium to form a spherical bead (or cylindrical bead in one dimensional trough) with near zero contact area with the micro-well surface 455 a.
  • Such near zero contact area beads, made of culture medium, are inoculated with of growing cell culture.
  • the beads behave as though they are levitated bio-reactors, hereafter; they are referred to by the acronym, LBR. They are levitated, because nearly the entire outer surface of the bead is surrounded by ambient environment exchanging with it metabolite gases with minimum impedance, as the arrow directions 456 show.
  • the LBR 452b in trough 45 Id is made to nearly float on the surface 455b that is perforated, mesh-like, porous or otherwise permeable to metabolites.
  • very small LBR beads having diameters in the range of 100 micron to 1000 micron large surface to volume ratios are achieved, thereby ensuring optimum gas exchange and highest productivity that exceed 100 mL/L or even exceed 500 mL/L.
  • LBR comprising diverse shapes and cross sectional areas 452c, 452d, FIG. 7B, may be produced with the supporting micro-well shapes 45 l e, 45 If, comprising shallow depths, and surfaces that are permeable to metabolites. They are designed to maximize gas exchanges to maintain high cell viability and density.
  • the illustrated shapes and cross-sections are meant to non-liming examples. Persons skilled in the art will be able to select other geometries that have advantageous features.
  • FIG. IOC illustrates an embodiment of layers 460, and 461, comprising a handle structure 460h, 461h, and a plurality of LBR's, 452e and 452f which have their surfaces in contact with the ambient environments for effective exchange of metabolites 456.
  • FIG. 10D illustrates an embodiment of a layer 462 comprising a handle structure 462h, at one culture chamber 452g, and a plurality of gas chambers 463 which are in communication with the culture through permeable surfaces or perforated surfaces covered with super-hydrophobic coatings 465. The latter ensures non-stick surfaces to enable the filling and emptying of the chamber repeated with minimum fouling.
  • the arrows 464 indicate the direction of exchange of metabolites which are designed to have short diffusion lengths and diffusion times, and maximum surface to volume ratio for high density and productivity.
  • FIGS. 9A-9F, FIGS. 10A-10D are non limiting examples. Skilled practitioners will be able to conceiver variations which will not depart from the inventive features taught by the 3D SansSoil farming paradigm, the TSA tower implementations, the TSA transport mechanisms, and the non-stick culture in the multi-layered arrangements of micro-well levitated bioreactors.
  • FIG.11 is an illustration of a TSA tower 400 that describes other aspects of the invention related to energy requirements to sustain plant growth. Specifically, it emphasizes the systems' flexibility in using diverse energy sources and forms, individually or in combination. Unlike conventional 2D agriculture which is constrained to use the only sun illumination, in the TSA system 400, direct sun energy is not a requirement, it is an option. When solar illumination is used with TSA, the system housing is designed to be transparent to the wavelength relevant to photosynthesis.
  • the system generally comprises strings of LED 421, localized near the growing plants in an optimized configuration so as to achieve uniform illumination. These LEDs are driven by means of an electronic subsystem that delivers to the plants light pulses comprising variable frequency, variable pulse widths, shapes, and duty cycles.
  • Applicant has used pulsed illumination to optimize the enzymatic kinetics that experimentally demonstrated improvements in the energy utilization efficiency ranging from 4 to 10, dependent on the plant species.
  • artificial illumination, and indoor controlled environment farming benefit from the ability to increase the photo synthetic efficiency by factors ranging from 10 to 100, AgriPAL, Eq. (1), above, and EVJ" ⁇ rf E ⁇ gj] E .
  • the LED's primary energy is derived from several electric power options shown in FIG.
  • Photovoltaic arrays which harvest and convert solar radiation to electric power, with efficiencies ranging from 10% to 20% or even higher.
  • This electric power is delivered to the pulse generating subsystem that drives the LED 421.
  • This option combines all the advantages of the 3D SansSoil TSA farming with the limitless availability of low cost renewable energy from the sun. The cost advantage is realizable especially when the PV arrays are placed on land that is not suitable for agriculture.
  • Wind turbine electric power generation is another source delivered to power the pulsed
  • LED strings 421 This option enables TSA tower farming for food production in remote areas on lands that are not suitable for conventional agriculture. Most advantageously in geographic locations where the temperature swings are very high and unpredictable. Whether these locations are in near arctic climates or very hot deserts, the TSA controlled environment will be suitable for efficient food and biofuel production.
  • Electricity from other renewable sources combined with LEDs is suitable for power system 400 including hydro power, geothermal, ocean waves and tidal.
  • Grid provided electricity in combination with LEDs is also suitable to power system 400.
  • Grid derives its electricity from coal, natural gas, other fossil fuels, and nuclear fuels.
  • the self-sufficiency and modularity of the contemplated system will enable easy scale up to larger production volumes, once a module is optimized in terms of yield, productivity per unit volume, resource utilization efficiency and low production cost.
  • a scaled up production system comprising plurality of modules that may be stacked vertically to any desired height, the "sky is the limit", the ultimate potential of 3D agriculture, realizing the goal of food and energy security with no resource competition.
  • the present invention comprises aspects of AgriPAL that deal with maximizing space utilization efficiencies, which include three dimensional, 3D, soil-less, SansSoil, plant growing structures and subsystems to sustain growth. More specifically, the aspects that reduce the cost of said structures and subsystems which lead to the minimization of the parameter f in Eq. (1). Even more specifically, the increase of g e E which is a function of the n, the number of vertical layers in 3D farming systems wherein the productivity and yield are measured in units of ton/hectare-meter-year, or ton/m3-time, or kg/m3-day.
  • the fundamental structures associated with these aspects are described herein with respect to FIG. 3 A.
  • the SanSSoil method for indoor growing plants and other photosynthetic organisms comprises the following steps:
  • the SanSSoil method further comprises the steps:
  • Computer system 500 includes a processor 502, such as a central processing unit, an input/output interface 510 and support circuitry 512.
  • processor 502 such as a central processing unit
  • input/output interface 510 and support circuitry 512.
  • a display 516 and an input device 516 such as a keyboard, mouse, pointer or touch- screen enabled input are also provided.
  • the display 516, input device 518, processor 502, and support circuitry 512 are shown connected to a bus 514 which also connects to a memory 520.
  • Memory 520 includes program storage memory 530 and data storage memory 540.
  • computer 500 is depicted with direct human interface components display 516 and input device 518, programming of modules and exportation of data can alternatively be accomplished over the interface 510, for instance, where the computer 500 is connected to a network and the programming and display operations occur on another associated computer, or via a detachable input device as is known with respect to interfacing programmable logic controllers.
  • Program storage memory 530 and data storage memory 540 can each comprise volatile (RAM) and non-volatile (ROM) memory units and can also comprise hard disk and backup storage capacity, and both program storage memory 530 and data storage memory 540 can be embodied in a single memory device or separated in plural memory devices.
  • Program storage memory 530 stores software program modules and associated data for operating said software program modules, for instance, for carrying out the AgriPAL conditions, enhanced EVI derived from the new Plant Growth Model, PGM, described herein.
  • Data storage memory 540 stores information concerning the correct amount of nutrients, the correct pH and the optimum environmental conditions for maximum yield.
  • the computer system 500 can be any computer such as a personal computer, minicomputer, workstation, mainframe, a dedicated controller such as a programmable logic controller, or a combination thereof. While the computer system 500 is shown, for illustration purposes, as a single computer unit, the system can comprise a group/farm of computers which can be scaled depending on the processing load and database size.

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Abstract

In order to achieve food and energy security, while at the same time eliminating the "food vs. biofuel" conflict, a transformational three dimensional multilayer farming, MLF, is presented. Soil-less indoor three dimensional multi-layer farming systems and methods are disclosed that are based of the Agriculture Profitability Assurance Law, AgriPAL, and the novel Plant Growth Model, PGM Each layer in the MLF system comprises at least one string of SanSSoil Growth Elements each of which carries out multiple functions to sustain plant growth. In addition, in certain embodiments layers comprise permeability features enabling sharing of resources to minimize the initial capital cost and the variable cost of consumables. In further embodiments a continuous flow farming method is provided for the production of material products comprising a traveling seed amplifier system which features the continuous planting of seed mass in planting layers, and synchronously harvesting an amplified mass.

Description

SOIL-LESS INDOOR FARMING FOR FOOD AND ENERGY PRODUCTION, INCLUDING HIGH DENSITY THREE DIMENSIONAL MULTI-LAYER FARMING, PERMEABLE THREE DIMENSIONAL MULTI-LAYER FARMING AND CONTINUOUS FLOW FARMING OF MATERIAL PRODUCTS
RELATED APPLICATIONS
[01] The present application clams the benefit of priority to U.S. Patent Application No. 13/887,333 filed May 5, 2013, entitled "SanSSoil (Soil-less) Indoor Farming for Food and Energy Production," U.S. Patent Application No. 13/887,334 filed May 5, 2013, entitled "High Density Three Dimensional Multi-Layer Farming," U.S. Patent Application No. 13/887,336 filed May 5, 2013, entitled "Permeable Three Dimensional Multi-Layer Farming," and U.S. Patent Application No. 13/887,337 filed May 5, 2013, entitled "Traveling Seed Amplifier, TSA, Continuous Flow Farming of Material Products," all of which are incorporated herein in their entireties.
BACKGROUND OF THE INVENTION
Field of the Invention
[02] This invention relates to improvements in farming for food and energy production.
Description of Related Art
[03] Will We Produce Enough Food to Adequately Feed the World?
[04] Advances in health sciences and technologies, in combination with better nutrition, are paving the path to nearly eradicate infant mortality while increasing life spans to beyond the present average of 80 years. Consequently, it is expected that the world population will swell to at least 9 billion by 2050. It has been recognized that such a level of projected population increase will pose a formidable challenges to our planet, stressing its already limited resources: food, energy, land, and water, and fomenting acrimonious competition and conflicts, to obtain and sustain good quality of life and lifestyle.
[05] These challenges have recently been highlighted by the United Nations' Food and Agriculture Organization, FAO, which published the findings of a High Level Experts Forum, in Rome, October 12-13, 2009, entitled "How to Feed the World 2050". Also in the June 15, 2011 Issue, C02-Science, published by the Center for the Study of Carbon Dioxide and Global Change, Dr. C. D. Idso, highlighted the challenges in his article entitled "Estimates of Global Food Production in the Year 2050: Will We Produce Enough to Adequately Feed the World?"
[06] Both the FAO and Idso reports reveal an alarming consensus: that a significant per capita reduction is looming, in global food production, arable land, water resources, and farm yields of staple food crops. To avoid the disastrous consequences, they point to the need for a radical paradigm shift in food production technologies, systems and methods. The present food supply- demand gap continues to have devastating consequences in many parts of the world, in the forms of hunger, mal-nutrition, and deaths. According to FAO, there are 1 billion hungry people in 2012. The projected widening of that gap will worsen by 2050 for a 9 billion population. In addition to famine in many parts of the world, geopolitical strife will also cause incalculable adverse effects on the welfare of humanity.
[07] These challenges are further magnified by the following three conflicts:
[08] Conflict # 1: Food vs. Less C02
[09] There are many who are concerned over global warming caused by carbon dioxide emissions. They have embraced the cause of curbing fossil fuel use and are advocating C02 reduction measures, and urging governments. They have influenced certain governments to act, and laws have been enacted attempting to discourage the use of resources that increase global C02. However, this position is in direct conflict with the need to sustain life and to feed the world, as a first priority. At present, 1 billion hungry people need urgent attention, growing to be 3-4 billion in 2050. It is puzzling contradiction that the "global warming" community relies of questionable photosynthesis models to predict dire consequences for humanity in 2100, yet they cannot use the same models to understand why plant food efficiency is <0.5% (Table 1). The full and accurate understanding may very well prove that more C02 is better at absorbing heat and at the same time deals with today's urgent need for food and biofuel. After all, C02 is the main ingredient for food and life itself (living mass is hydrocarbon matter).
[10] Conflict # 2: Food vs. Fuel
[11] Direct consequences of the global warming mitigation are the mandates imposed by the US and EU and other countries to produce C02 neutral transportation fuel from biomass, biofuel. This presents yet a second conflict with the priority of feeding the world. It is feared by many that biofuel exacerbates the problem by diverting already scarce resources normally dedicated to food production: arable land, water, seeds, fertilizers, herbicides, farming tools. The food and energy price pressures that ensue will make it even harder for many vulnerable segment of the global population to close the nutrition gap. It is feared that their numbers will increase. It is also in conflict with achieving both food and energy security. This food vs. fuel debate continues unabated.1
[12] Conflict # 3: Food vs. Forest Land
1 http : / / en. wikipedia. org/ wiki/Food_vs . _fuel [13] As shown in Table 1, plant scientists, and agronomists agree that the measured efficiency is -0.5%, however, they cannot fully account for all the -99.5% losses, i.e., the where these losses originate. As described below in more details, the full accounting for these losses is the key to inventing ways to minimize them.
[14] Plants store solar energy in the form molecular bond energies of carbohydrates, sugars, starches, cellulose and proteins. The economics of conventional farming to profitably produce generally affordable staple foods (sugars, cereal grains, legumes, leafy vegetable, and tubers such as: potato, yams, cassava) relies directly on the zero cost of solar energy, ZCOE. This forces cultivation outdoors, on two dimensional lands, because the solar radiation is delivered in units of Watt per unit area (hectares, acres, or square meters).
[15] The reliance on this ZCOE has therefore, forced conventional agronomy to succumb to accepting -0.1 to 0.5% efficiencies (see Table 1 ). One of the main factors leading to such low efficiency is the need to use the soil to support plant growth, and soil borne nutrients which are not easily controlled. This lack of control makes soil a liability rather than an asset. The main concern breeder's have, when producing a new variety, is the specific environment (geography) and the soil mineral composition. This means instead of having one optimum seed that fits all, they will need to produce an astonishingly large number of cultivars of a particular specie in serve as wide market as possible. Even then, production cost constraints will require compromise. This is a consequence of uncontrolled outdoor soil based agriculture.
[16] In addition, the reliance of ZCOE, meant accepting the adverse environmental conditions by seeking appropriate hospitable geographical locations that supply water, solar radiation and tolerable temperature swings.
[17] Therefore, because of the reliance on ZCOE, the growers and the food production enterprises have limited or no control. This in turn has lead to the requirement of enormous resources that are inefficiently used, including: insatiable demand for two dimensional arable land, water, fertilizers, and pesticides. To accommodate the population increase from 1 billion in 1800 to the present, -7 billion, required deforestation at a high rate. On a global scale, once again fearing that deforestation adversely impacts the issue of global warming, governments are enacting laws and mandates to restrict increasing farm land by deforestation. This is the third conflict with the priority to feed the world, and achieving energy security.
2 http://arpa-e.energy.gOv Portals/0/Documents/ConferencesAndEvents/ Past Workshops/ ABTF%20Workshop%20- %20Ort%20Presentation.pdf Table 1 Efficiencies of selected crops
Annual solar energy conversion efficiencies of C3
and C4 agricultural crops.
Crop Type Yield Efficiency
t ha y"1 (%)
Elephant grass Pennistum purpureum C4 88 0.8
Sugar cane saccharum officinarum C4 66 0.6
corn zea mays C4 27 0.4
beet beta vulgaris C3 32 0.5
rye lolium perenne C3 23 1.7
potato solanum tuberosum C3 11 0.3
[18] Conventional Agriculture Methods
[19] As is well known, since its invention, agriculture is generally practiced in the form depicted in FIG. 1A, two-dimensional outdoor soil-based farming. This includes the essential elements of food production: i)- the sun; ii)- 2D field, an area covered with soil that mechanically and physiologically support plant growth; and iii)-water irrigation source, and nutrients. This is referred to as arable land that combines adequate quantities of sun, water, and nutrients which generally come at no cost. The supplemental nutrients or fertilizers, when added, carry a relatively low cost. As demonstrated by AgriPAL described herein, this form of farming has been profitable because the main ingredients come at little or no cost.
[20] In recent years, the adoption of indoor controlled environment agriculture, CEA has increased. An exemplary prior art reference is US Patent 3,931,695 which gives a good description of CEA. In CEA, the growth area is sheltered, making the control of many plant growth parameters possible, thereby achieving higher yields and higher resource utilization efficiencies. The increased use of soil-less hydroponic or aeroponics nutrient delivery practices increased the economic viability for growing many plants. FIG. IB illustrates the elements of CEA, also referred to as greenhouse. When solar illumination is used, CEA is the same as conventional sheltered farming with the added benefit of protection from the weather and better control of pesticides, nutrients, and water. When temperature control is added, yields can be enhanced and many planting cycles become possible year round. When artificial lighting is used, extending growth periods to 24 hours per day becomes possible.
[21] Applying AgriPAL as discussed further herein in conjunction with the present invention, has shown that this growing method of farming, while growing in acceptance, is economically viable for certain high value added plants. It is not possible to economically (profitably) produce staple crop or biofuel using known indoor farming because of the added daily energy consumption for heating or cooling, and the cost of the added infrastructure. The objects of the present invention are inventive aspects that make indoor farming viable even for staple foods.
[22] Most recently, Van Gemeret et al. taught 3D farming system in US Publication 2011/0252705, October 20, 2011 which is depicted in FIG. 1 C. The system resembles stacking many edifice floors vertically, resembling the greenhouses in FIG. IB but placed one on top of the other. The most prominent features of this vertical farming concept are: i)-higher productivity per unit area; ii)-the plants in each floor are independent of the plants of neighboring floors; iii)-the floors do not share resources (light nutrients) directly; iv)-constrained to use only artificial lighting; and v)-the ceiling height, h, of each floor makes the system highly inefficient in terms of productivity per unit height. The economic viability is possible only for high value added products like tulips, cut flower, etc. As will be shown in more details, the present invention addresses these limitations, by means of making growth layers in the form of networked strings that are coupled to each other sharing light, and nutrients, thereby compressing the vertical height needed for growth by factors ranging from 5 to 50.
[23] There are numerous other proposals for 3D vertical farming, but none addressed the issues of cost reduction, understanding photosynthesis energy efficiency, vertical space utilization efficiency, and other resource efficiencies in order to make staple food and biofuel production economically feasible. More specifically, they do not meet the AgriPAL profitability
ROE
condition described herein, Eq. (1) except for very high priced products, i.e., for = > 100.
COE
[24] FIGS. 1D-1H illustrate conventional plant growing methods having distinct environments, (elements) 50a-50e, each of which comprises, a plant 53 illuminated by sunlight 51. They are distinguished by the type of growing medium, the plant mechanical support, and the method of delivering nutrients to the plants. In the case of elements 50a, 50b and 50e, the soil provides the support and nutrients are delivered directly to the soil which are them up taken by plant roots.
[25] In the case of element 50c, the hydroponic method well known in the art is used comprising, a mechanical structure 54, (container) for growing one or more plants. The container is filled intermittently (or continuously) with nutrients 55, and the plant up takes the nutrient through a porous root support structure, 52a. This root support structure replaces soil.
[26] The aeroponics method, 50d, also known in the art, comprises a plant support structure 56, through which the roots penetrate to bottom space 57c, where the roots are sprayed directly by means of nozzle 57. This method is known to achieve better yields than the soil based and the hydroponic systems because the roots are in direct contact with the ambient oxygen. Its main disadvantage is the low vertical space utilization efficiency and the spray nozzle clogging.
[27] In all the cases, the roots are feed by a plurality of different physically separated components (discrete instead of integral components). Also all of these elements feed the roots indirectly from the bottom.
[28] Liabilities of Soil Based Outdoor Agriculture
[29] The high cost of the involuntary dependence on solar energy is discussed herein; enticed by the zero cost to ensure economic viability outdoor farming. One of the consequences is forcing conventional agronomy to succumb to accepting -0.5% and as low as 0.1% efficiency, TABLE 1. This afforded little or no control over the energy efficiency, ηΕ , to make further improvements beyond what has already been achieved in the last 50 years, -20 times yield improvements, the fruits of the Green Revolution that started in 1950s.
[30] Going forward, perhaps only fractional gains may be realized, which are offset by higher per capita demand. The low efficiency and lack of control of nutrients, and other elements in outdoor solar-based and soil-based farming have lead to the requirement of enormous resources that are used inefficiently including: insatiable demand for two dimensional arable land, water, fertilizers, and pesticides.
[31] Therefore, a need exists for improved agricultural structures, systems and methods that overcome the aforementioned conflicts and problems.
SUMMARY OF THE INVENTION
[32] The present invention is related to the field of agriculture, horticulture, agronomy and agro-economics of food, energy, and other organism made substances. It is specifically related optimizing plant, yields, photosynthetic energy conversion efficiency as well as the utilization efficiencies of other resources, including, time, space, water, and nutrients. Even more specifically, the invention is related to indoor, environmental controlled farming in three dimensional (3D) spaces, vertical farming, without the reliance on the sun energy or soil.
[33] The invention also addresses the need to solve problems associated with conventional outdoor two dimensional farming which is projected to limit its ability to achieve food and energy security for humanity.
[34] Described in detail herein is information expounding the limitations and liabilities of conventional soil-based agriculture, and inventive teachings of alternative soil-less indoor three dimensional multi-layer farming that are based of the Agriculture Profitability Assurance Law, AgriPAL, and the novel Plant Growth Model, PGM. [35] In certain embodiments the present invention is related to 3D farming systems comprising a plurality of layers each of which is capable of sustaining the growth of plants.
[36] In certain embodiments the present invention is related to 3D farming systems in which the plurality of layers are permeable in the sense they can permit water, nutrients, light, shoot and roots of neighboring layers to pass through the layers.
[37] In certain embodiments the present invention is related to 3D soil-less farming for enhancing volumetric productivity and 3D yield by means of continuous flow agriculture capable of synchronous daily planting, harvesting and amplifying of material products, MP, including plant-made-products, PMP, and culture made products, CMP, used for food, biofuel, medicine, and high performance industrial materials. The species used for the culture and production of CMP include individual living cells, microorganisms, employing cell methods of production. The species can be naturally bred, wild, or genetically transformed by means of transient, plastid, or nuclear recombinant engineering methods. The specific use of the word plant, as in plant layers, and plant growth elements, is not meant to limit the scope of the broad inventive features that apply generally to a broad spectrum of growing material products.
[38] Together, AgriPAL and PGM present for the first time, mathematical and analytical foundations, based on scientific principles, that describe how photosynthesis works, and presents formulas for predicting yield, energy efficiency, and agronomic profitability. They unraveled mysteries that to date eluded and baffled plant scientists and agronomists. They revealed the notion of solar gain, and astonishingly high physiological gains which can be garnered by means of better underrating of resource utilization efficiencies. These gains increase the yields and efficiencies by more than 10 fold and a path to approach and exceed 100 fold.
[39] In order to solve the formidable food and energy problems and challenges facing humanity and eliminating the contradictory conflicts, a transformational departure from conventional agricultures is needed. Conventional agricultures is constrained to be in the outdoor open field environment. This constraint is a consequence of the reliance on zero cost of solar energy, C02, and water for photosynthetic to produce biomass for food and energy. The path to the solutions of the aforementioned problems is abandoning outdoor soil-based agriculture that requires enormous supplies of arable lands and water resources. Following this new path provides great benefits which include: eliminating the lack of control over nutrients, 1000 times water saving, eliminating adverse environmental conditions, and soil-borne pathogens.
[40] Instead of conventional two dimensional, 2D, outdoor farming, the object of this invention is to teach means and methods to profitably harness the third dimension where unlimited space is available, where soil is avoided, and water can be conserved. The inventive 3D agriculture according to the present invention focuses on utilizing the third dimension efficiency by teaching devices, systems and methods to compress the vertical space needed for food production.
[41] The teachings according to the present invention of 3D farming is the partitioning of the third dimension into a plurality of layers (multi-layers) each of which is capable of being supplied with nutrients, and the light needed to sustain growth. Said plurality of layers are supported by means of a 3D structure that comprises a master system comprising subsystems which are designed to optimally provide water, light, nutrients, C02, 02, and temperature controls for specific plant organism species.
[42] Said plurality of layers comprise strings of interconnected soil-less (SanSSoil) growth elements, SGEs, each of which is integrally made to have a multi-function capability including: germinating the seed, growing the plant, providing the plant with physical structural support, water, nutrient, light, and capability to sense the plant environment.
[43] The strings of SGEs are disposed in the first, second and third spatial coordinates. They are in the form of one dimensional network, two dimensional network or three dimensional network supported by the multilayer structure.
[44] An aspect of the invention is resource utilization efficiency such that staple foods and bio-energy are produced profitably so that the food and energy supplied with no "food or fuel" competition problem. This is accomplished by means of inventive features described herein that enable the plants in each SGE in string networks to share resources including: light, nutrients, and intra-layer space. This is the multi-layer permeability property taught according to certain embodiments of the present invention.
[45] Another aspect of the present invention is making the each SGE and the string interconnection and space between strings optically transparent or permeable so as to enable light to pass through plurality of layers to share, conserve and efficiently utilize light. This will minimize the need for many light sources, thereby reducing product cost.
[46] Another aspect of the present invention is avoidance limitations of prior art method of growing plants to reduce cost to enable economical staple food production.
[47] Another aspect of the present invention is saving vertical, intra-layer space by enabling the plant root and plant shoot sharing. This means the roots of plants one layer, can occupy (share) the space of the shoots (leaves) of the layer below.
[48] Another aspect of the present invention is the traveling seed amplifier, TSA, system and method which enables high through put continuous flow farming of MP, that have wide spectrum of applications including: all foods, biofuel, medicines, and high performance industrial materials. Key features of TSA include the continuous -synchronous or semi- continuous planting and harvesting MPs at high rates, ranging from 1 to 10 times per day, or at compressed time periods much shorter than the specie dependent seed to harvest time, rsth .
[49] Another aspect of the present invention is compressing the vertical space resulting in much higher volumetric productivity, ton/hectare/meter, than prior art vertical concepts discussed above, and illustrated in FIG. 1 C. According to the present invention, there are at least three ways to achieve vertical compression of the average interlayer spacing hav which include: i)-the use of ultra-compact integrally constructed SGEs assembled in string networks; ii)- enabling the shoot-root space overlap; and iii)- the TSA system and method which automatically adjusts the traveling interlayer spacing according to the age of the growing plant.
[50] Another aspect of the present invention is providing a totally sealed system for growing plants for food and energy comprising inventive sealing features and mechanisms to recycle water and nutrient resources to maximize utilization efficiency and reducing cost. For example, the natural transpiration of water is recaptured and reused. The plant growth environment is maintained at a desired temperature and relative humidity for optimum plant performance. The result is water saving by reutilizing between 100-1000 times water which would have been wasted in conventional outdoor agriculture.
[51] Benefits of sealed 3D growing systems include the avoidance of the unpredictable weather conditions which results in a reliable food production with losses due to weather. The sealed growing 3D system can be made aseptic, pathogen free, adding yet another path to profitability assurance.
[52] Another aspect of the present invention is harnessing the limitless vertical space in combination with the TSA and continuous flow agriculture to construct high rise edifices, and tower structures extending upward tens of meters or even hundreds of meters in the sky, enabling the production of MP, food and bio-fuels without competition for space resources, since the vertical space is limitless. The TSA towers may be illuminated by the sun, artificial lighting, such as LED, or a combination of both.
[53] Yet another aspect of the present invention is the construction of TSA towers
(Hs meterhigti) in pairs, comprising 2N layers, so that the first tower comprises a planting
(input) port at the bottom and the second tower comprises a harvesting port (output) also at the bottom. In operation seed or seedling layers are inserted in the planting while mature plant layers are synchronously harvested from the harvesting port. To accomplish this synchronous continuous flow farming, a transport means is provided to transport the layers from the planting port to the top of the first tower, transferring layers laterally to the top of the second tower, and finally transporting the layers downward for harvesting at the bottom harvesting post of said second tower.
[54] Another key aspect of the present invention is TSA tower pairs featuring vertical compression factors in average interlayer spacing, hav , ranging between 2 and 10, and temporal
h
compression factor , r¾ =— -—— , speeding up the synchronous planting and harvesting periods
2HS N
by 10 to 100 times and even 100-1000 times.
[55] Yet another aspect of the present invention include sealed 3D growing system or TSA tower systems that are aseptically sealed by providing load locks to the planning and harvesting ports and automation means to control physiological and environmental and physical parameters for optimum MP growth conditions.
[56] Another aspect of the present invention is the isolation of the sealed 3D growing system or sealed 3D growing TSA tower system from the external environment thereby protecting said environment. This is especially beneficial when growing genetically transformed plant species (GMO) for experimental and production purposes.
[57] Yet another aspect of the present invention is the ability of one layer to water, and nutrients from the strings of SGE in said layer, to strings of SGEs in the plurality of lower layers. This is a unique feeding mechanism that is distinct from well know prior art hydroponic and aeroponics mechanisms
[58] Yet another aspect of the present invention is the utilization of artificial lighting, preferably LED, instead of solar lighting. More specifically, LED lighting that is delivered to the plants as pulses of short duration, between 0.1 ms and 2.5 ms, and frequencies between 30 Hz and 300 Hz. Applicant discovered that the enzymatic kinetics of the plant physiology can be made 4-10 times more efficient by temporal control the light.
[59] Yet another aspect of the present invention is the control of the spatial placement of LED illumination sources within the 3D growing system in order to maintain uniform illumination received by the growing plants.
BRIEF DESCRIPTION OF THE DRAWINGS
[60] The invention will be described in further detail below and with reference to the attached drawings. They are not intended to be restrictive or limiting as to sizes, scales, shapes or presence or absence of certain necessary components that are not shown for brevity but are, nonetheless, well known to those skilled in the art. In the drawings, the same or similar elements are referred to by the same number. The drawings include: [61] FIGS.1A-1 C describe conventional farming methods, including outdoor soil based farming, indoor CEA (greenhouse) farming and 3D vertical farming;
[62] FIGS. 1D-1H illustrate the various environments which plants grow into and specifically how nutrients are delivered to the plant roots;
[63] FIGS.2A-2C show experimental photo synthetic response of two lettuce varieties and strawberry plants to the variation of light intensity, PAR, and carbon dioxide levels. These reveal the saturating or limit level phenomena of the inputs;
[64] FIG. 2D is an illustration of the fine temperature control and its impact on the saturating response of photosynthesis;
[65] FIG. 2E shows the photosynthesis response of pulsed illumination at different periods, revealing a high cut off frequency analogous to a high pass filter;
[66] FIGS. 2F-2H illustrate the photo synthetic temporal responses of various plants under pulsed illuminations, revealing temporal gain factors ranging from ~3 to -10;
[67] FIG. 3A illustrates a SansSoil indoor farming system comprising a protected environment for sustaining plant growth, and a control subsystem that follows a program to control the growth;
[68] FIG. 3B-3C shows more details of the system of FIG. 3 A, that is comprised of multilayer each of which comprises a network of strings of SansSoil Growth Elements, SGEs, showing the localization of each element in the 3D space, first, second and third spatial coordinates, and how they periodically repeat with periods px, py, pz;
[69] FIG. 3D-3E describe more details how each SGE is made, its structures and function;
[70] FIGS. 3F-3K describe how SGE are interconnected into strings, which in turn from layers of plurality of strings all networked to from a 3D growing system shown with respect to FIG. 3A;
[71] FIGS. 4A-4H describe the integrally made single SGE and its commutations with its neighbors sharing resources including light and nutrients to support growth;
[72] FIGS. 4I-4M describe the integral SGE and SGE strings with plant growth in various orientations;
[73] FIG. 4N illustrates the possibility that strings of SGE may interconnected into series and parallel network combinations in communication with resource supply sources;
[74] FIG. 4P shows a plurality of exemplary configurations to attach SGE to supply sources, and to neighboring SGEs;
[75] FIGS 5A-5B illustrate SGEs allowing plants to grow upside-down;
[76] FIGS. 6A-6B illustrate delivery subsystems to multilayer SGE networked strings, showing light delivery from the support walls of the main structure; [77] FIGS. 6C-6E show main system housing protective structures configured to various sections;
[78] FIG. 7A describes multi-layer permeability of light, enabling layers to share light from common source;
[79] FIGS. 7B-7C describe the multi-layer permeability of shoots, and roots sharing space of neighboring layers;
[80] FIG. 7D illustrates the multi-layer permeability to fluids delivering nutrients to plants from a common source, whereby the fluids are in the form of fog, mist, sprays, and streams;
[81] FIG. 8A describes the multi-layer tower traveling seed amplifier, TSA, system for continuous flow agriculture;
[82] FIGS. 8B-8E describe typical plant growth trajectory curves, defining key parameters to illustrate the inter-layer vertical space compression system of TSA;
[83] FIG. 8F describers the flexibility in locating the planting and harvesting ports attached to the TSA tower housing;
[84] FIG. 8G describes a variation of a TSA system wherein the layers move horizontally instead of vertically;
[85] FIGS. 9A-9B illustrates the variable pitch screw TSA transport mechanism which automatically maintains appropriate interlayer spacing according to plant age;
[86] FIGS. 9C-9F describe an embodiment of a TSA system showing various components;
[87] FIGS. 10A-10D are illustrations of a composite TSA layer comprising a plurality of trays in the form of 2D SGE arrays for cell cultures on super-hydrophobic coatings; and
[88] FIG. 11 describes the diverse energy sources which may be used to drive the operation of the TSA tower, to drive strings of LED, control the climate and to deliver nutrients to sustain plant growth.
DETAILED DESCRIPTION OF THE INVENTION
[89] In view of the above, the reliance on the sun has one asset, which is ZCOE. However ever it has many liabilities. There is therefore a need to resolve the above conflicts in order to achieve both food and energy security for humanity. One means of achieving this, which is one of the objects of the present invention, is teaching radical inventive farming methods that eliminate the lack of control of outdoor farming by abandoning the ZCOE dependence and its associated use of soil related liabilities, as well as scarce arable and two dimensional lands.
[90] The present invention is generally related to growing or amplifying martial products, PM, including, PMP, and CMP. The specific use of the word plant, as in plant layers, and plant growth elements, is not meant to limit the scope of the broad inventive features that apply generally to a broad spectrum of growing material products.
[91] In the present application, the term "SanSSoil" refers to an enclosed indoor farming method that eliminates the need for soil. In many SanSSoil embodiments, the sun is also optionally eliminated as the main light source for photosynthesis. In other SanSSoil embodiments, the sun may be used alone or in combination with artificial lights. In many SanSSoil embodiments, three dimensional architectures are found to be most advantageous. The use of the third dimension enables the productivity metric of yield per cubic meter to be used, and the means to maximize it are sought, leading to minimum use of land area.
[92] More specifically, the inventive solutions presented herein, have been inspired by Applicant's discovery of mathematical analytic expression, referred to as AgriPAL (agriculture profitability assurance law), which gives deep insight, for the first time, as to why conventional outdoor farming has been profitable since its invention ca 10,000 ago. This insight afforded by AgriPAL, to date, has been opaque to plant scientists and agronomists. It makes transparent the relationship between the plant yield, the physiological efficiencies of resource utilization and their direct impact on the economic viability of food and biofuel producing enterprise. Even more specifically, the discovery of a solar gain factor gsol , which together with the physiological energy conversion efficiency, ηΕ reveal the economic viability index, EVI = rfEgsol which must approach or exceed the value of 1, in order to achieve profitability.
[93] The key insight is what happens in indoor farming, when artificial lighting is used, and we must pay for the energy. In this case, gsol→ 1 and EVI→ ηΕ which is such a low value taken from Table 1 making indoor not economically viable from many crops, especially staple crops and bio-fuels. The present invention solves this problem, by teaching (thanks to AgriPAL) how to obtain another gain factor, ge , (substitute iorgsol) , in the absence of the sun ( gsol→\ ) that leads to an enhanced viability index: EVI"≡ . This, according to the many aspects of the present invention, makes EVE≡ ^ge→ 1 , thereby ensuring profitability for indoor (sunless, soilless) farming even for staple food and biofuels.
[94] The knowledge gained from Applicant's AgriPAL leads to:
1. Abandoning the sun and the soil and uncontrollable outdoor farming. 2. Adopting inventive controlled environment indoor SanSSoil architectures.
3. Proof that the novel SanSSoil architectures can be economically viable, EVIe≡^ge→\ . 4. Said architectures are naturally suited to three dimensional environments, since the sun is no longer relevant.
5. The sky now is the limit; arable land is no longer a problem.
6. Therefore, since competition between food and biofuel for land, both food and energy security are achievable without the above three conflicts.
[95] Need for Sound Scientific Fundamentals
[96] Relying on the status quo, the above three conflicting debates are not winnable. The main reason is that they are based lack of or at best, they are based incomplete fundamental scientific and economic understanding of the food enterprise. Exemplary evidence to support this conclusion is gleaned from this quote: "Farming is not a moneymaking proposition in an industrial economy. Never was, never will be." This quote is attributed to Gene Logsdon, a veteran expert in the field agronomy, and the author of 20 books, and numerous publications.3
[97] Of course, it is evident that his position on the viability of the farming enterprise is not supported by the facts; more that 10,000 years of food production that sustained human population growth.
[98] Another example is found in the article entitled: "Diagnosing a Farm Profitability Problem."4 The author deals with nearly every conceivable parameter, except those which deal with the physiological efficiency of the plant, and the role ZCOE of the sun plays in the profitability. Imagine diagnosing a patient without the knowledge of the patient's physiology!
[99] In their report NREL/TP-580-24190, entitled "A Look Back at the U. S. Department of Energy's Aquatic Species Program— Biodiesel from Algae,"5 Sheehan, et al., present an extensive expert assessment of farming and harvesting algae for bio-fuel, and specifically present deep science-based discussions of the impact of the photo synthetic solar energy conversion efficiency. They point to the fact: "Not enough is understood about what the theoretical limits of solar energy conversion are."
[100] Yet another report related to the photosynthetic efficiency and productivity of algae cultivation entitled "A Realistic Technology and Engineering Assessment of Algae Biofuel Production,"6 Lundquist et al., conclude: "Unfortunately, much of the current interest in algae oil production is based on a lack of understanding of the science underpinning this technology, and on a misreading, or lack of reading, of the prior technical reports."
[101] More specifically, as will be shown herein, there has not been a credible attempt to fundamentally understand energy conversions efficiencies and utilization efficiencies of other
3 http ://www. landinstitute.org/vnews/display. v/ ART/2002/06/21 /3 dl a6b900f801
4
http://www. uaex.edu/Other_Areas/publications/PDF/FSA-9512.pdf
5 http://www.nrel.gov/docs/legosti/fy98/24190.pdf
6 http://digitalcommons. calpoly.edu/cgi/viewcontent. cgi?article=l 189&context=cenv_fac resources, including: water, space, time, C02 and primary and secondary and trace micronutrients. The most scientifically advanced credible attempts (discussed below) are unable to fully and accurately account for all the 99.5%-99.9% plant losses (Table 1). Gaining full understanding will be the enabling catalyst that achieves inventive engineering solutions to realize the "feed the world" mission while resolving the above conflicts. By simply increasing the average global efficiency to 1 %, the yield per hectare of staple food can be doubled. This path will produce enough food to adequately feed the world and enough biofuel to energize the world, thereby achieving both food and energy security for inhabitants of the planet, not just the rich and powerful.
[102] 1.1 Known Scientific and Technological Facts
[103] From a scientific perspective, giving the proper nutrition resources, plants will grow reproduce and propagate and proliferate. They are indifferent as to how these resources are delivered to the plants or where they came from. It is now an established fact that plants can grow indoors by means of modern controlled environment agriculture, CEA, methods. The adoption of CEA is accelerating, in view of its numerous benefits including: increased yield, pest elimination, lower water demand, lower nutritional demand, and species specific nutrient recipes. It has also been established that, in advanced CEA, plants thrive under artificial light, with soilless, SanSSoil, aeroponic feeding techniques.
[104] Therefore, from established fundamental scientific facts, neither sun nor soil are exclusively required for growing food, leading to the logical conclusion that arable land should no longer be the limiting resource. In other words, there are alternatives to the sun and soil. We can grow anywhere, including in the third dimension where space is unlimited. In indoor 3D CEA farming edifices, which can be sealed, water molecules are not allowed to escape. The water produced by the transpiration process can be condensed and recycled, which results in water savings of at least 100 times relative to conventional outdoor 2 D farming.
[105] Plants grow photosynthetically by converting light photons mostly into hydrocarbons. The building block (simplest) of hydrocarbon is glucose sugar which has the chemical formula (CH20)6 . Based on the law of mass conservation; the plant requires only 6 water molecules
H20 and 6 carbon dioxide molecules C02 to produce one glucose molecule. In addition, each cell has a water content of 60-80% of dry weight. It is possible to recycle all the water that is not stored part of the dry biomass. Therefore, using a totally sealed environment, the water requirement for farming can be reduced by at least two orders of magnitudes.
[106] Water availability, therefore, is not the limiting factor. Therefore with sealed indoor farming, we have a great opportunity to grow food everywhere, including in the most arid lands and deserts, provided a small amount of water is used most efficiently. [107] Based on energy conservation laws, it has been established that for every C02molecule is assimilated by the plant, about 10 to 12 photons are required from the light source. The plant light harvesting machinery has evolved to its present optimized capability. This optimization is stored in the genome of the plant as certain genes which perform "evolutionarily conserved" functions throughout the plant kingdom. This function is the same whether the organism is a single cell algae, sugar cane, or giant red wood tree. This function has been optimized around the selective spectral absorption of the chlorophyll molecules. Although, these molecules, and the plants can thrive in light near the blue region of the spectrum, -400 nm and near red -680 nm, they do not necessarily need the blue energy.
[108] This reveals how much energy is squandered by farming outdoor, relying on solar radiation. It also presents an opportunity, according to aspects of this invention, for indoor "sunless" farming using only a single wavelength chosen from a low cost highly efficient source, including light emitting diode, LED, that gives a narrow light band near 650 nm. Of course a blue LED can be used but that will be wasteful and costly. At present, plant investigators are debating the role of blue radiation for indoor farming.
[109] 1.2 the Premises of the Present Invention
[110] First Premise: Facts
[111] The conclusions based on the above fundamental scientific and technological facts are summarized as follows:
[112] The sun is not necessary, artificial light is a viable alternative.
[113] The Soil is not necessary. Plants have been shown to grow anywhere including zero gravity outer space.
[114] Only 6 water molecules for every glucose sugar unit, makes water not limiting, especially when water recycling means are used. This is a great opportunity to save water,
[115] Indoor faming is more efficient and better controlled than outdoor farming especially avoidance of pests.
[116] Food and biofuel energy security are achievable, resolving the above three conflicts.
[117] Second Premise: The Discovery of Farming Profitability and Economic Viability
[118] While the conclusions 1 -4 above are based on scientific, engineering measureable facts, the conclusion 5, however, lacks the agronomic or agro-economic support. More specifically, the realization of conclusion 5 must satisfy economic viability (profitability) conditions which have made conventional solar-based outdoor farming profitable, since its invention, -10,000 years ago. This success economic viability success has been responsible for sustaining human life and population growth to the present - 7 billion. [119] However, there has not been a quantitative analytical definition of the economic viability index, EVI, that comprises measurable parameters and the predictive power to determine what makes a farming enterprise viable (profitable). If existed, it would enable the decision much easier, to launch a new enterprise, improve and expand exiting ones, or even to disband those that are not viable. This is especially true in the burgeoning field of algae based bio-fuels (also called third generation biofuel). The obstacle encountered in formulating the EVI, has been the difficulty in accounting for solar energy that comes freely with no cost, ZCOE. Because of this ambiguity, it is believed that many biofuel start-up companies had to liquidate, and many others, at present, are hoping to survive on the basis of claims that are not supportable.
[120] Applicant's research and analysis have concluded that the absence of EVI that accounts for the ZCOE, the reason for the absence of a viable plant growth models. Such model would explicitly quantify farming productivity, relate it to intrinsic energy conversion efficiency, as well as physiological aspects of plant growth, and explicitly accounts for the absorbed solar energy. The inability to account for the ZCOE of the sun has resulted in the lack of transparency of EVI and is believed to hinder better understanding of agro-economics of farming. The inability to account for the ZCOE has also hindered progress to resolve the above three conflicts, which would have paved the way to realize the mission of food and energy security.
[121] Therefore, in order to clarify why outdoor farming has been viable for so many years, Applicant has succeeded in formulating an agro-economic law called: Agriculture Profitability Assurance Law, AgriPAL described by this mathematical expression (Section II): The economic viability index, EVI, is defined as:
[122] ΕνΐηΕ (^) = η^ο1ατ . (1)
^ other
[123] The second premise of the present invention is based on Eq. (1), and embodies an inventive method that enables the linking, of the economic parameters, profit, p, fixed cost, f, variable cost, v, to the organism (plant, algae, other photographs) energy conversion efficiency, ηΕ , including a gain factor, gsolar = (—— ) , wherein, ssol , is the solar energy consumed per
^ other
cycle and, sother, all other energies consumed. If the latter incorporates f + v energy equivalents, ε ROE
then Eq. (1) becomes: ηΕ (—— ) =≥ (1 + p) . The value of this conversion efficiency
S other COE
parameter, ηΕ , is not only species dependent, but also variety (cultivar) dependant. Each cultivar is optimized by breeding and propagation methods to exhibit desirable traits for specific geographical locations, and regional soil conditions. The growers, however, have no control over this outdoor parameter ηΕ , once they purchase the seeds (embryos) suitable for their location and environment.
[124] Over the years breeders, plant scientists, and agronomists have succeeded in increasing % by about 20 times in the case of staple food. The Green Revolution of the 50's and 60's is attributed to this success. It staved starvation in many countries. The increases in ηΕ provided profitability assurance, and made many countries food self sufficient, including: the USA, Mexico and India.
[125] Unfortunately, increases in ¾have slowed to a halt, triggering the alarming dire predictions related to our ability to feed the world in 2050. Optimistically, breeders, plant scientists and agronomists, are using modern tools to reverse the trends and to increase ηΕ . Tools used include: faster, cheaper genome sequencing, bio-engineered organisms that exhibit novel desirable traits encoded in their transformed genomes, plant cell culture, and accelerated breeding though double haploid technology to produce stable pure breeds.
[126] Applicant's AgriPAL is another contribution which links the physiological aspects of ηΕ to the economic viability index for outdoor farming. It has enabled Applicant to teach herein several inventive embodiments related indoor farming which emulate the economic viability of outdoor farming as clarified by AgriPAL formula.
[127] AgriPAL explicitly reveals EVI as the quantity: rjEgsolar , with gsol as the solar gain, without which, farming is not profitable. It requires that J Egsolar approach or exist 1, so that the condition in Eq. (1) is satisfied. Applicant derivation of the new AgriPAL reveals transparently, unambiguously, and explicitly, for the first time, role the sun plays in an agronomic formula even though the cost associated with solar energy is zero. It also enables the accurate accounting of all other energy sources, sother , which include, hydrocarbon, electrical, mechanical, and chemical sources.
[128] This second premise of the invention is the method that made EVI transparent and explicit. It revealed for the first time, that even though the energy efficiency can be as low as 0.005 or even as low as 0.001(table 1), EVI as whole can approach the value of 1 and may even exceed 1, because gsol»\, enabling the profitability condition in Eq. (1) to be satisfied. The solar gain factor gsol may exceed 1000, since it is possible to realize in certain situations sotherto be very small, or even vanishingly small.
[129] The ability for the first time to understand and quantitatively and explicitly account for why conventional outdoor solar-based farming has been economically viable (profitable) for millennia is the only path to replicating said economic viability of indoor farming with artificial lighting, in the absence of the sun, according to inventive aspects of the present invention. More specifically, the realization of the conclusions 1 -5 of the first premise now becomes possible as a result of the full understanding of the agronomic factors afforded by AgriPAL Eq. (1).
[130] Third Premise: Indoor Farming Profitability and Viability
[131] This is related to combining conclusions 1-5 of the first premise with the knowledge of EVI and its connection to the agronomic parameters, of AgriPAL, Eq. (1) from the second premise. More specifically, using AgriPAL, to enable the establishment of an economically viable indoor (sun-less) food production enterprise, based on artificial lighting. The success of this indoor enterprise emulates or modeled after the already proven viability outdoor farming that enjoys zero solar energy cost.
[132] The combination of conclusion 1 -5 with AgriPAL paves the way to the practical and profitable realization of indoor farming for food and energy security mission, without the three conflicts. This is the third premise, the third piece of the puzzle needed to achieve that mission, by methods and means inventive indoor farming (for staple and other foods), according to the present invention. Such indoor methods and means emulate the profitability and success of conventional solar energy-based outdoor farming, for affordable staple food production, according to the following logical sequence:
a. Set ssol = 0, so that EVI→ ηΕ which is the ratio of output energy divided by the input energy repressible for photosynthesis, wherein ¾ is for a cultivar bred for outdoors.
ROE
b. When ssol = 0, the condition, ηΕ = > (1 + p + / + v) is impossible to be
COE
satisfied (non economically variable) for indoor farming of commodity staple foods, because
ROE
ηΕ ~(0.005)x(2) is clearly much less than 1, from Table 1. c. Must provide a means to produce a gain factor ge for indoor farming that emulates the role gsol plays in outdoor farming, such that the union of this new gain factor ge and
ROE
ηΕ will satisfy the new condition g ]E =≥(l + p + f + v) .
COE
d. Embark on research and analysis that will make the physiological and physical components ηΕ more transparent, so as to enable us to fully account for all the losses and the bottlenecks and invent means and methods to transform and enhance ¾ , to become e. Find inventive methods and systems that lead to an enhanced energy conversion efficiency ηΕ> ηΕ for cultivars bred for indoors, with an enhancement factor or gain factor defined by: ηΕ≡ ge E≡ EVV , the enhanced economic viability index EV .
f. With the
Figure imgf000021_0001
, determine which organism cultivar (micro- organism strain) and growing system, that satisfy the AgriPAL condition:
ROE
EVIe =≥(\ + p + f + v) , and realizing the highest profit margins
COE
g. Finally, determine the minimum value of e¾ that enables the profitability assurance of farming commodity staple foods and bio-fuels derived from them.
h. With step g satisfied, the mission to produce all foods and bio-fuels with no competition, according to conclusions 1-5 of the first premise, is now accomplished.
[133] The third piece of the puzzle, the third premise, is predicated on the successful ability to achieve step d: Embark on research and analysis that will make the physiological and physical components ηΕ more transparent, so as to enable us to fully account for all the losses and the bottlenecks and invent means and methods to transform and enhance ηΕ , to become rfE≡ gj]E≡ EVIe . This is one of the key aspects of the present invention.
[134] This has become necessary because of the failure of prior art teaching (as shown the fourth premise below) in the full understanding and accurate accounting for all the 99.5% losses (Table 1) and its inability to relate these losses to all the physiological and physical components responsible for the growth mechanism. Therefore, this would make it possible to invent means and methods to achieve ^≡ ge E≡ EVV necessary for profitable indoor farming and for obeying the AgriPAL condition, according to the present invention.
[135] Note the distinction in notation:
Parameters in, rfE≡ gj]E≡ EVV , that have small "e" refer to the enhancement required for indoor farming according to the present invention that satisfy the AgriPAL viability condition.
Parameters in, rfEgsol≡ EVI , without the small "e" pertain to conventional outdoor cultivars that are un-enhanced and have exemplary values in Table 1.
[136] Fourth Premise: Prior Art Model Limitations
[137] The state of the art level of scientific understanding of plant efficiency is highlighted in a recent article entitled "Improving Photosynthetic Efficiency for Greater Yield" by Zhu, et al, Annu. Rev. Plant Biol. 2010. 61 :235-61. This, to date, is the most extensive treatment addressing the yield from the point of view genetic traits of plants which have been improved by ever improving breeding methods including genetically engineered organism with improved stress (water, hear, pathogens) tolerance. Since the genetic trait-based yield increases have slowed considerably, the authors point to need to investigate the physiological photosynthetic efficiency, the enzymatic biosynthetic factors, as the most promising path to resume the increase of productivity.
[138] The authors describe the yield by the following equation:
Y 0.487 - S: (2)
where, St (GJ m-2) is the total incident solar radiation across the growing season, sj is the light interception efficiency, sc is the conversion efficiency, and ερ is the partitioning efficiency also termed harvest index, is the amount of the total biomass energy partitioned into the harvested portion of the crop. The authors also reveal that this equation does not match the yields observed in the field. In fact deviations between theoretical potential and average experimental observations, of 500% and 6500% for C4 and C3 plants exist.7
[139] In addition to the theoretical and experimental deviations, prior art models which describe the conversion efficiency ^ , do not offer explicitly and sufficiently detailed transparency of the basic physiological aspects of plants. Specifically, they do not account for temporal information that is inherent a dynamical growing system that comprises a plurality of dynamic subsystems including: several enzymatic biosynthetic reactions that lead to cellular doubling, building all the machinery necessary for absorbing energy, converting and storing energy, and reacting to environmental stimuli and stresses in a manner that ensures survival of the organism. Many of these kinetic functions take place in sub-millisecond time scale, while others take longer times ranging from seconds to hours.
[140] While it is recognized that it takes 10-12 photons to assimilate one C02 molecule, this happens at very low light level, far away from the saturating intensity. Near or above this saturating intensity, losses increase significantly. As shown below, Applicant discovered that these losses are related to the temporal mismatch between the fast reactions PS II & PS I and the slow Calvin (Rubisco). Applicant measured these losses to be between 4 and 9 and reclaimed as gain in aspects of the present invention.
[141] Therefore, in view of the above limitations of prior art energy efficiency models, there is an urgent need for an alternative working model that better reveals, more transparently, the η
(http://arpa-e.energy.gOv Portals/0 Documents/ConferencesAndEvents PastWorkshops/
ABTF%20Workshop%20-%20Ort%20Presentation.pdf ) ;
http://\¥ww.sebiology.org/education/slides/lancaster/Neil_Baker.pdf plurality of the basics components of the organism, that the accounts more accurately for the losses experienced by plant systems.
[142] More specifically, the new model must be able to achieve step d of the third premise in order to successfully emulate the profitability success of solar-based outdoor farming. Even more specifically, the new model should enable to accurately measure the temporal and spatial aspects of the organism. Such an accurate model will enable scientists and engineers to provide innovative systems and methods that improve plant productivity, and ensure both food and energy security to do away with the "food or fuel" conflict.
[143] Fifth Premise: Inventive Plant Growth Model, PGM
[144] According to step d of the third premise, seeking an inventive method and means to emulate the profitability success of conventional solar energy-based outdoor farming requires the an enhanced energy conversion efficiency, ηΕ> ηΕ ^ realized, with an enhancement factor or gain factor defined by: rfE≡ gj]E≡ EVV . Prior art teaching according to Eq. (2) does not reveal the requisite physiological transparency that even hints at the possibility of achieving a gain factor ge > 1.
[145] The fifth premise, therefore, is Applicant's Plant Growth Model, PGM, that has enough plant physiological details to enable engineers to conceive inventive farming methods and systems with ge > \ . The detailed derivation of PGM and its agronomic applications are presented in Section III. The key inventive methods and means are embodied in the following equations:
iE = ^ I Psal = {^GMB {∞)^ - e -^ )-\ l {Psalrslh )-\ ( 3)
and, the standard PGM form for outdoor solar based farming:
'/ ξφ ^ ] (4)
i=\
^ = Π^=^ΑΑ„ΑΓ S≠oton (4α)
i=\
ξ = ξ9ξ,ξί (4 )
obeying the outdoor AgriPAL Condition:
• Y
Ssol ROE
n. (λ + η
COE
Figure imgf000023_0001
and the enhanced PGM form, applicable to the inventive indoor farming according to the present invention:
Figure imgf000024_0001
≠' = gt≠ = tlg1S1 = tlg1 tlS1 (5a)
i=l i=l i=l
' (' 4 (5b)
obeying the indoor AgriPAL Condition:
ROE
/ w . - ( l /' · . · )
CUE
with ΕΥΓ≡ E≡g^E where, represent those parameters, members or
Figure imgf000024_0002
components which play functional role in the physiology of the organism, and Eq. (4a) groups the members of the sets §i m 5 mto related at
Figure imgf000024_0003
least six groups including:
1 · k^m = ^C02 ^H20^02
■ SNSPS1 K
4. SBr
« e _ e e e e v
J - ^env ^soil^pH^T^ weather^ pest
Figure imgf000024_0004
and their corresponding respective enhancements groups from the set ge .
[146] One or more members of a group may be combined with members of one or more of the remaining groups to form a new group for the purpose of constructing a means and or method for achieving^≡ gj]E≡ EVV , with ge > 1 , in order to satisfy the profitability condition AgriPAL for the present inventive indoor farming. This affords many levels of control and the ability to obtain the necessary gain to satisfy Eq. (1).
[147] The detailed functions and roles of members of the groups or subsets in plant physiology are given in more details in the form of non limiting examples in Section III. It is understood that other members or parameters that affect the physiology of the plant properties may be included, including: taste, flavor, color, aroma, toxicity, medicinal or nutritional values. Others may be related to recombinant transformation of genomes permanently or transiently by means of introducing specific single genes or stacked genes (polygenes) that affect single or multiple traits, signaling or regulatory functions, resulting in the enhancement of rfE≡ gj]E≡ EVV , with ge > l . Yet others may include environments (x-ray, UV, viral etc.) to influence mutations, permanent or transient that may affect the enhancement^≡ gj]E≡ EVV , with ge > \ .
[148] As will be shown below, gain, ge > \ , and more specifically the gains in ranges 2-5; 5-10;
10-100; and at least 100, may be obtained with the new means of controls, according to aspects of this invention. In certain aspects of the invention, enclosed indoor controlled environment is used with solar illumination such that a gain factor gegsolar such that a hybrid EVIh = J Egegsolar can be made to exceed 1 , using solar illumination alone, artificial illumination alone, or a combination of the two. In either case, it is possible to employ methods and means to increase
Ssoi =— ~ by decreasing sother , the sum of all other direct energies plus energy equivalent of
^ other
direct costs. The latter are computed by the dividing them by a reference COE. The energy equivalent direct costs so converted include components of / and v in Eq. (1), leaving only the indirect cost components of / and v in the right hand side of Eq. (1).
[149] Using one or more of the components, in an appropriate combination, from the groups,
SmSiSiiSenvSBr photom md sp t f i it will be shown in the present application that there are several means, methods and systems that lead to achieving^≡gj]E≡EVIe , with ge > 1 by means of enhancing one or more components from that group . It will be shown that rfE≡ gj]E≡EVV , with ge > l , can be increased to a level as to satisfy the profitability, according to AgriPAL, of indoor farming systems with artificial lighting.
[150] More specifically, the profitability of 3D multi-layer faming systems, with only few layers, that can achieve ge in the range of 5 to 10. Such an enhancement has been demonstrated experimentally by Applicant. In other embodiments, ge , in the range of 10-100 can be derived from the enhanced %sp%t f group.
[151] As will be shown below, gain, ge > \ , and more specifically the gains in ranges 2-5; 5-10;
10-100; and at least 100, may be obtained with the new means of controls, according to aspects of this invention.
[152] The laws of energy and mass conservation are strictly adhered to, that restrict g iE≡ EVI" to be less than one. There are many ways of increasing geto large values, but must always reach a limiting value (asymptote) such that the product g^E≡ EVI e may approach 1 but ROE
never exceeds 1. According to AgriPAL, must always be larger than 1, to ensure
COE
profitability. This statement reveals that any enterprise that relies on converting light energy,
ROE
biomass derived energy, must have >1.
COE
[153] 1.3 Food & Energy Security without Three Conflicts
[154] The inventive embodiments of the present application are based on the above five scientifically based premises. They afford deeper insight leading to a much improved understanding of the plant physiology, energy conversion efficiency and their relationship with temporal and spatial domains in the microscopic (micron, ms) and macroscopic (meters, hours days) scales. They provide transparency of the role each of plurality physiological parameters play, thereby, allowing engineers to identify and fix bottle necks in a focused manner.
[155] This unprecedented knowledge is the source transformational departure form conventional thinking leading to the surprising inventive features of the present invention. More specifically, by persistently pursuing the accurate quantitative accounting for the loss mechanisms, 99.5%, surprisingly, led us to the conclusion that an improved farming method meeting the food and energy needs (staple commodities) for 9-10 billion people, must discard the old agronomic two dimensional, 2D, farming methods and its direct reliance on the zero cost of solar energy and soil based growth. This reliance, since 10,000 BC, constrained growers to succumb to its unintended limiting consequences, the liabilities of ZCOE.
[156] Furthermore, the reliance on ZCOE and soil based outdoor farming, means uncontrolled farming, which we call "what-you-see is what-you-get, WYSWYG" farming. In this case, the farmer has no control over the key resources needed for the growth. More specifically, he has no control over the main ingredients: solar intensity, temperature, water, C02 levels, soil minerals, extreme weather conditions or pests.
[157] Instead, abandoning this traditional farming, leads to novel three dimensional, 3D, multilayer indoor farming which can be engineered to be efficient, and profitable even for the production of commodity staple foods.
[158] In conventional 2D outdoor farming, the annual 2D yield (2D plant productivity) is measured in tons or kg per 2D area units (hectare, acre, or m2). Whereas, the 3D yield (3D volumetric productivity) is measured in units of kg per m3.
[159] More specifically, discarding or departing radically from old agronomic 2D farming, the new inventive model, systems and methods, eliminate the reliance on the four most important pillars of farming:
The sun is eliminated as the main source of direct plant energy • Soil is eliminated as the medium for growing plants
• Requirements of farming geography with ample of water no longer valid
• Profitability requires cultivating minimum land area about 250 hectares, in agronomically advanced regions.
[160] It is shown that when one is no longer bound by the above four pillars of farming, totally new inventive engineering solutions become possible. The direct consequence of this departure is increasing plant productivity by more than 10 fold, thereby, achieving both food and energy security while resolving the three contradictory conflicts.
[161] The consequences of adopting a new mindset of 3D indoor farming with no sun, and no soil, and 3D metrics, are the following surprising conclusions:
1. Sugar cane is the most farmed food, representing 21 % of all farmed products. It has an annual 2D yield of -80 ton/hectare, with - 10% sugar content, and grows to a height of 4 meters. Sugar beet has average 2D yields of 50 ton/hectare, with - 25% sugar content, and grows to a height of 0.8 meter. By converting 2D to 3D yields, is evident that sugar beet has a much higher productivity than sugar cane as found from: [(0.25)(50/0.8)] /[(0.1 )(80/4)]=7.8. Surprisingly, this overturns the previous wisdom that sugarcane is the most productive plant for ethanol biofuel.
2. According to the present invention, the indoor 3D farming of sugar beet is energy efficient and profitable, then multi-layer 3D farming with 10 to 100 layers produces sugar for food and fermented into ethanol biofuel, without infringing on additional land. This alleviates the concern over more deforestation and resolving the food vs. fuel dilemma.
3. By exploiting the third dimension for multi-layer (skyscraper) farming, there will no longer be a limitation of arable land to feed the world or to produce biofuel to energize the world.
4. With 3D indoor farming, because it can be made sealed from the outside world, the water requirement is reduced by least two orders of magnitude.
[162] Therefore, the new farming paradigm, according to the present invention, focuses on mathematical analysis, and better fundamental scientific understanding of plant efficiency, and accounting relatively more accurately for the losses.
[163] II. Agriculture Profitability Assurance Law, AgriPAL
[164] Humans invented farming circa 10,000 BC, transforming their lifestyles from, hunter- gatherers, to settlers in farms, villages and towns. Farming was primitive. It was based on manual labor, assisted by animals and primitive tools. Farm productivity, yield, was low until the 19th century innovations introduced in England, benefiting from the Industrial Revolution, that increases in yield were realized. Innovative farm tools and machineries, as well as chemical fertilizers, are among the key contributors to better farm productivity.
[165] The evidence that farming has been profitable is supported by the fact it sustained population growth to the present level. This conclusion applies to the smallest family farm and the largest farms measured in hundreds and even thousands hectares. However, many farmers, economics, agro-economic scholars, scientists and accountant continue to debate productivity and profitability using primitive concepts and tools. The simplest tool is the spread sheet model that subtracts all the costs from the revenues of all farm products, to arrive at the profit. Attempts have been made to model profitability by means of mathematical analytical tools. Since farming depends on the geography, country and its farm policies, the models are applicable locally.
[166] Known teachings concerning farm productivity and profitability models fail to relate farm profitability and productivity to the plant physiological efficiency and its use of energy from the sun, labor, and other consumable fuels. Accounting for ZCOE has been the key obstacle encountered by known teachings. This obstacle has lead to incomplete understanding of farming economics. It would be nearly impossible to meet the challenges posed above without a universal tool that accurately relates all the parameters to the economic viability of growing food and biofuel energy, a tool that accounts for the role the ZCOE plays relative to the other resources. The solar energy is the primary source, but because it comes for free, it is absent from prior art accounting models.
[167] There is, therefore, a need for a universal mathematical methodology that possesses the predictive ability to assess profitability in terms of farm resource utilization efficiencies, including the physiological energy utilization efficiency ηΕ . This would be valuable tool for planning, policy making, pricing, selection of product mix, etc. Most importantly, it will enable inventors and innovators to focus on the real bottlenecks to be able to conceive optimum engineering solutions.
[168] Applicant discovered such a mathematical law called: Agriculture Profitability Assurance Law, AgriPAL. Applicant has recognized the general importance and utility of this law as an inventive tool to agronomy. The inventive embodiments of the present application are based this AgriPAL tool.
[169] More specifically, in order to accurately evaluate the economic viability and profitability of various farming and energy enterprises, the energy centric analysis and derivation of the novel, AgriPAL is embodied in the following formula:
( ε.
R()l': ' ( ! /' · ./ · v) (1)
COE
[170] [171] The most prominent feature of this law is it's the success, for the first time, in accounting for the solar energy ssol , which is available, at zero cost to all farmers, and other phototrophic k organism growers. It is incorporated into AgriPAL through the gain other sother = ^ st (non solar) energy sources sj , directly related to the production of biomass energy as the product.
These sources include: fuel energy for machinery, biomass feed stock energy content, manual labor energy, thermal, energy, mechanical, and chemical. The cost of each of these inputs, is converted to an energy cost equivalent, through an appropriate energy cost conversion factor in
( ε„ Y ROE
units of COE. Eq. (1) is simplified to: ηΕ \—— ≥ (1 + p) , if (/ + v) is also incorporated s other J COE
Figure imgf000029_0001
[172] COE , is the average cost of all input energy, sources directly used to produce the products, in units of, $/kWh, ROE , is the average return on energy, revenues from energy contents of all the products produced at the prevailing market prices, in units of, $/kWh, p, is the profit divided by the total energy cost, f, is the total cost attributable to the fixed capital equipment expense, CAPEX, and other fixed costs, divided by the total energy cost, and v, is the total variable operating costs, OPEX, divided by the total energy cost.
[173] The economic viability index, EVI, is defied as: ΕΎΙ≡ηΕ {——) = f]Egsolar is the key
^ other
parameter that measures whether or not the system or an enterprise can be profitable by testing if EVI · RCR meet the condition given by AgriPAL equation, where RCR is the ratio of the return on energy (the revenue for each kWh sold) to the cost of energy; thus: RCR≡ = . For
COE
indoor farming, in the absence of solar energy, according, to several embodiments of the present invention, control means and methods are described to enable EVIe = ^ge to be increased in order to approach unity, thereby allowing EVIe · RCR to satisfy the AgriPAL condition.
[174] Note that AgriPAL described in Eq. (1) is energy centric in that all the terms are dimensionless ratios of energy quantities or ratios of cost of energy. Since food (energy for life) and energy in general are used synonymously in this treatment, AgriPAL is a valuable tool, that in this form, or in its more general from (not presented here), is used as an inventive algorithm for the determination of the economic viability and profitability if all food or energy producing enterprise. [175] AgriPAL states that unless that condition is met, the enterprise is not viable. For food and energy enterprises, it made the energy parameters transparent, and at a quick glance, a conclusion can be made. For example, even though, from Table 1, ηΕ -0.005, the solar gain gsol
> 200, is more than enough to offset the low efficiency, thereby satisfying the profitability condition. In the case of highly mechanized large farms, the fossil fuel energy (diesel) quantity, intermittently used, to run the machines for only few days, is negligible relative to the quantity of solar energy absorbed and stored by the plant over 100 day cycle. In this case the profitability is assured. In the case of sugarcane, field data suggests that gsol between 2000 and 4000 are achievable.
[176] For a very small family farm, gsol> 200 also assures profitability, because the farmer relies of human and animal muscle energy intermittently, the quantity of which is negligible relative the quantity of solar energy absorbed and stored by the plant over 100 to 1000 day cycles.
[177] Recently, many biofuel start ups filed for bankruptcy shattering the dreams of all stake holders, entrepreneurs, employees, society, and investors. Using AgriPAL as a tool, it has been shown that these enterprises failed to meet the profitability condition, because they relied on biomass and sugars as input feedstock but did not accurately account for it. This caused a big distortion of the facts, thinking that profitability was possible, when in fact, fundamentally it is not. In other words, they did not consider this feedstock as energy that should have been a k
component insother =∑£t in our AgriPAL tool. In fact, this bio-mass energy component is larger than the other components. If these enterprises had AgriPAL tool available, they would have not started these enterprises in the first place.
[178] There are tens of biofuel companies which are operating on the assumption that they can be profitable. In fact they are violating the AgriPAL condition. They are mislead by the argument that one day fossil fuel will be so scarce that they can price their product higher to match that of fossil fuel, thereby assuring them profitability. According to our AgriPAL, RCR will remain nearly unchanged, i.e., the price tracts their cost of energy which is pegged to fossil fuel. More on RCR tracking is discussed below.
[179] Practical Applications of AgriPAL
[180] AgriPAL states that unless that condition, in Eq. (1) is met, the enterprise is not viable. For food and energy enterprises, it made the energy parameters transparent, and at quick glance, enables one to reach interesting and valuable insight. It is a tool to help lower the risk of decision making: to launch a new enterprise, to expand, relocate, to improve product mix, to leverage product mix, compete better, to reduce cost by many means.
[181] The following examples have relevance to the present invention, as they highlight the limitations of prior art and place the inventive features in their proper perspective.
[182] Example 1 : Profitability Conventional Farming Commodity Staple Foods
[183] For farming commodities (staple foods) including: cereals, soybean, sugar from sugarcane and sugar beet, tubers, potatoes, yams, and cassava, the right hand side of Eq. (2) can be shown to be at least 1.3 (marginally profitable enterprises). The global market determines the commodity prices, which range between $0.25/kg and $0.5/kg. These crops have an average intrinsic energy content ~$3kWh/kg. The cost of diesel is ~$0.08$/kWh, while the cost of solar energy is zero.
ROE
[184] From this, it is determined that = is between 1 and 2. This ratio is nearly constant
COE
because it deals with energy and food which are globally determined and track each other in equilibrium. The ratio, ^ changes dramatically only in temporally and spatially localized temporary situations, such as war in the Middle East or severe droughts in food producing regions. Since from the above discussions it is know that ηΕ -0.005, satisfying the AgriPAL condition requires that, gsol , to be between 130 and 260.
[185] Thanks to the zero cost solar energy, farming all kinds of food is always profitable, even the most affordable, lowest priced staple foods. The gains, g∞/ >100 can be maintained in the most advanced farming regions utilizing the most sophisticated efficient modern farm equipment with minimum labor energy. On the other hand, farming in underdeveloped regions, depends on muscle energy of humans and animals to maintain g∞/>100 and be profitable even in small farm lands. This gsol>\00, is one of the key contributions discovered by Applicant that predicts, through AgriPAL, the profitability of outdoor solar farming, that sustained human population growth to the present level.
[186] It is the same AgriPAL that is used, according to the present invention, to predict the profitability of indoor farming without the benefit of the sun, ( gsol =\, in this case), requires another gain factor, ge , to substitute for the absence of gsol . The new gain factor, ge must be high enough to satisfy the AgriPAL condition. This aspect of the present invention is shown in Section III to be possible.
Oliver Wyman, White Paper, "Food/Fuel Price Dynamics: Developing a Framework for Strategic Investments," 2010 [187] gsol is replaced with that which generated according to many preferred embodiments in the present application.
[188] Example 2: Profitability of Green House Farming with Solar Energy
[189] From Example 1, if the same commodity staple foods are grown indoors, green house, and assuming the advantages of two crops per year is afforded, Eq. (1), is transformed thus:
f X ROE
ι ( i · /> " ) (ic)
V. C other J COE
[190] Even though the productivity is increased by a factor of 2, ηΕ and ^ remain unchanged, but the gain, gsol , is much reduced from -100, to low levels approaching 10, or even less than 5, and may approach 1. This reduction in gsol , is a result of the significant increase in , k
ε other =£ ! that includes new terms for heating and cooling energy, electric energy, and fuel energy and direct labor. Furthermore, the right hand side of Eq. (lc) shows an increase in the green house capital cost as reflected in the increased value of /' . The reduction of gsol , and the increase of /' , while the ηΕ remains unchanged, prevents the AgriPAL condition from being met for commodity products (food and biofuel).
[191] It is therefore concluded from this example that indoor (green house) farming for commodity staple crops is not economically viable. It will be shown that one of the key aspects of the present invention is reversing conclusion in connection with indoor farming of commodity staple products. It is accomplished by replacing or augmenting gsol with another gain factor, ge , that is generated according to many preferred embodiments of the present and co-pending applications. In the process, the present invention will show hopeful paths toward feeding the world, one of major challenges posed in Section I.
[192] Example 3: Profitability of Green House Farming for Other Foods.
[193] Other foods defined here as farm products which are not staple commodity foods described Example 1. Especially foods or crops for which the seed to harvest cycle time can be short, in the range of 30 to 60 days to enable more than n plantings each year. These crops include leafy vegetables, herbs, and others, which are not produced for their seeds, and therefore, are harvested before flowering. For these products, Eq. (1) is transformed to:
ί„ Y ROE
ηη ≥(\ + p + f' + v). .(Id)
\ S other J COE [194] In this case the problem associated with the term gsol approaching 1, is compensated for by n= 3 to 10 and by the relative pricing flexibility (not available for commodities) leading to a
ROE
much higher = 50 to 100. This high value also benefits from the relatively low energy
COE
content -0.3 kWh/kg of these products, and a relatively higher flexibility in setting the prices
$2/kg to $5/kg. In the commodity case, = does not depart from between 1 and 2, as these
COE
are globally set and the producers (farmers) do not have much control over that.
[195] The conclusion of this Example 3 is that green house farming of non-commodity food products profitability, is not only assured according to AgriPAL, but can be very lucrative.
[196] Example 4: Profitability of Indoor Farming with Artificial Light
[197] The advent of high efficiency lighting systems, especially light emitting diodes, LED, has encouraged indoor farming without the reliance on the sun. There are many teachings in the patent literature of systems and methods to grow crops with artificially lighting. For this case, our AgriPAL Eq. (1) is transformed thus:
ROE
ηηπ =≥ (1 + p + f" + v) (le)
E COE
[198] The gain gsol becomes 1 because the solar energy, ssol→ 0 is eliminated. However, the fixed CAP EX cost component, /" , is much higher due to the LED cost which replaces the zero cost sun. In this CEA, n reflects the number of crops per year, increasing the yield.
[199] Assuming an optimum engineering effort that designs such a system to minimize
(\ + p + f" + v) to ~2 (marginally profitable), ηΕ -0.005 remains unchanged, and n~3, it is
ROE
required == >133. This illustrates that for artificial lighting indoor farming profitability is assured if the product price is high. There are many such products that satisfy this condition, leafy vegetables, herb, fruits, flowers, and plants used for medicinal purposes such as vaccines where = exceeds 1000 and may exceed 10,000.
COE
[200] This another exemplary illustration of AgriPAL value according to Eq. (l e), to assist the evaluation of decisions launch indoor farming with artificial lighting, product selection, and pricing such products to ensure profitability.
[201] Example 5: The Profitability According to the Present Invention
[202] Examples 2, 3, and 4, highlighted the challenges associated with growing staple commodity foods indoors, and why Example 1, outdoor field farming is the only presently available viable option for growing staple food to feed the world. This viable option is for the continuous reliance on the zero cost solar energy, and its associated drawbacks of large land and water requirement and their inefficient utilization. In addition, the outdoor farming constraint, subjects the growers to environmental risks of unexpected crop losses due to various factors, including: microscopic pathogens, weeds, droughts, floods, and extreme unseasonable temperature variations.
[203] Therefore, one of the main objects of this invention is presenting an alternative to outdoor solar based 2D farming. The inventive farming systems and methods are based on the five premises presented in Section I that enable the replacement of the sun and its gain ∞z with artificial lighting and an enhancement gain ge . This will ensure profitability not only for staple food according to AgriPAL, but also enables the productions of all other crops with much higher profit margins than previously possible by prior art methods.
[204] The combination of the five premises, presented in Section I, the discovery of AgriPAL, the gain factors g∞/ and ge generated by our new model, the PGM, described by Eq. (4) increases to astonishingly and surprisingly high levels heretofore thought unattainable. Described herein are several inventive embodiments which result in enhancement factors, ge ranging from 5 to 10, and in other embodiments, from 10 to 50. Yet in other embodiments, ge ranging from 50 to 500 is possible. These gains will offset the low prior art efficiencies which may be in the range of 0.001-0.01, in Table 1 , that are constrained by the outdoor constraints of soil and sun dependencies.
[205] Because of the enormous plant diversity, conversion efficiency values vary from species to another, and even within varieties of the same specie. These variations are a result of environmental conditions, stresses and intrinsic traits of a cultivar bred for a specific geography and soil conditions. The examples presented herein, are used for illustration of the systems and methods and are not intended to be liming.
[206] III-The New Plant Growth Model, PGM
[207] In Sections I and II Applicant elaborated on the significance of AgriPAL and specifically in elucidating the reason why conventional farming has been viable and profitable that it has sustained population growth to the present level. AgriPAL discovery lead Applicant of the present invention to an inventive methods to determine agro-economic viability of food growing and energy producing enterprises. The method is a tool heretofore unavailable to aid these enterprises in making rational decisions based on source science and agronomy practices, reducing their risks to launch, expand, improve or disband said enterprise. [208] In Section II, there are presented a number of examples highlighting the challenges associated with growing staple commodity foods indoors, and why that is not possible if one relied of the limited prior art understanding of the efficiency, ηΕ , concluding that outdoor field soil-based farming is the only presently available viable option for growing staple food to feed the world, and growing biofuel, energy for transportation.
[209] This viable outdoor option is for the continuous reliance on the zero cost solar energy, and its associated drawbacks or requiring vast resources that are not utilized efficiently. In addition, the outdoor farming constraint, subjects the growers to other consequences; environmental and economic risks, unexpected crop losses due to microscopic pathogens, weeds, droughts, floods, and extreme unseasonable temperature variations.
[210] The inventive contributions herein change all of that with new transformational framing paradigms.
[211] AgriPAL takes the following three forms:
A. The solar-soil-based outdoor farming: EVI · RCR≥ (1 + p + / + v) (6) ,
B. The artificial lighting indoor farming : EVIe · RCR > (1 + p + f + v)e (6a) , and
C. The hybrid solar enhanced indoor farming: EVJh » RCR > (! + /? + / + v)h ....(6b) with : EVI≡ ηι SSOI E>
V. C other J
EVE≡η ≡g E ,
Figure imgf000035_0001
AgriPAL may also take an alternative form by incorporating in sother, the energy equivalents of / + v.
[212] III.1 Global Stable Equilibrium for RCR
[213] According to Idso, op. cit, nearly 75% of all foods grown to sustain life are commodity staple crops: {Sugarcane and sugar beet} account for -25%; cereals: {maize, rice, wheat, barely, oat, rye, millet, sorghum} account for -34.5%; while tubers: {potatoes, cassava, sweet potatoes, and yam} account for 10.5%; and Oil seed crops account for -5%.
[214] Growers of these commodity staple crops that feed the world have no control over pricing of their products. The global commodity market sets these prices. A prolonged drought in Australia or in China will increase the price to the rest of the world and adversely disproportionately affects the poorest in Africa and Asia. [215] The same conclusion is reached in the case of the other commodity, the energy, the price of which is established by the global commodity market.
[216] Therefore, for commodities, the average RCR, the ratio of the return on energy ($/kWr) to the cost of energy ($/kWh) remains nearly constant and hovers close to the values between 1 and 2, depends on the nature of the crop and its geographical sources.
[217] The RCR ratio remaining within that range signifies that food and energy are tightly coupled commodities. Data exists9 tracing the commodity prices of food and fuels. For instance, the cost increase of diesel or other fuel used for machinery will reduce farm profitability, according to AgriPAL, Eqs. (1 , 6), from the reduction both and (VCOE ).
s other J
Therefore, the product price will increase to turn a profit, keeping RCR within that range, which seems to be a natural stable global equilibrium value.
[218] Another insight into the global equilibrium of the RCR is gained from Brazil, which is the largest sugarcane producer with 38% and the second largest producer of sugarcane ethanol. Because of its market share leadership one would expect that it can control pricing and RCR. This is not the case. If demand for sugar increases, or supply decreases because drought in France affecting sugar beet supply, prices will increase, tempting the Brazilians to shift to producing more sugar because it is more profitable.
[219] This in turn reduces, the supply of ethanol causing its price to rise. The latter energy price rise will increase the price of other energy sources affecting other farms products. The end result is returning RCR to the global stable equilibrium.
[220] Government forces, legislate, or dictate, or intact polices and laws have traditionally upset this equilibrium. These events include embargoes, trade wars, tariffs, mandates to use bio- fuel, or to reduce C02 emission. Even, in this case, RCR will stabilize perhaps at a higher or lower level artificially set to an equilibrium value within an average range.
[221] This RCR equilibrium discussion is relevant to the present invention because it amplifies the significant of the AgriPAL, Eq. (6s, 6a, 6b), and the surprising results that emanate from it. More specifically, having established that food growers, bio-fuel producers, and other and energy producing enterprises, have no control over RCR, in order to accomplish the mission of achieving both food and energy security, with no conflicts or resource competition, the only parameters available to us are :
Figure imgf000036_0001
Outdoor b other J
9 Oliver Wyman, White Paper, "Food/Fuel Price Dynamics: Developing a Framework for Strategic Investments," 2010 Indoor Ενΐ'ηΈ8.ηΕ ί
Indoor with Sun EVIh≡ηΕ≡ ge gsoflE
[222] The three EVI expressions comprise the energy conversion efficiency ηΕ . We have learned to accept that the cost of the high plant nutritional diversity to sustain human life is the low biosynthetic conversion efficiency as shown in Table 1. Our discovery of AgriPAL Eqs. (1 , 6) uncovered gsol > 100, that compensates for that low efficiency such, that gsoflE , together is high enough to satisfy the AgriPAL thereby successfully sustaining human life for thousands of years.
[223] Nearly 75% of staple food production is a consequence of this successful union perfect gsoflE >1 , leading to affordable energy, proteins, vitamins, and other nutrients for the well being of all humans. The improvements attributed to gsol , stem from the inventive farming mechanization solutions as well as creative agronomic practices that enabled the production of enormous quantities at lower labor cost, and lower waste.
[224] The improvements attributed to ¾ , emanate from advances in biology, photosynthesis process, chemical sciences and technologies and bioengineering enabling the understanding and optimization of nutrient requirements, low cost fertilizer manufacturing, pesticides, and transformation of genomes, and breeding methods. These together lead top increases of annual yields per hectare about 20 fold.
[225] This accelerated steady growth of crop yields spawned the Green Revolution of the 50' s and 60' s is attributed to this success. It staved starvation in many countries, provided profitability assurance, and made many countries food self sufficient, including: the USA, Mexico and India.
[226] Unfortunately, increases in gsoflE axe slowed to a halt, triggering the alarming dire predictions related to our ability to feed the world in 2050. Optimistically, breeders, plant scientists and agronomists, are using modern tools to reverse the trends and to increase gsoflE .
Tools used include: Faster, cheaper genome sequencing, bio-engineered organisms that exhibit novel desirable traits encoded in their transformed genomes, plant cell culture, and accelerated breeding though double haploid technology to produce stable pure breeds.
[227] Now that the improvements through gsofiE union are no longer realizable, succumbing to its mandatory requirement of farming outdoors to enjoy the zero cost of solar energy is revealing its detrimental consequences. [228] There is, therefore, a need for a new economic viability index, an alternative to conventional EVI = gsoflE , that will enable indoor farming (sans soil, sans sun) with artificial lighting, thereby eliminating the detrimental consequences of soil-sun-based outdoor farming. This new enhanced index is our EVJ"≡ ηΕ"≡ g ]E resulting from PGM and realized by inventive means and methods according to the present invention. It meets the condition to produce not only affordable staple commodity foods but also relatively higher price food, and other high value added products.
[229] The high value added products include: plant made materials, proteins, nutraceuticals, and pharmaceuticals, vaccines. For example, recently shortages of guar gum (from guar bean) for industrial use such as oil and gas hydro -fracking production methods caused the prices to jump 10 fold. The material is a polysaccharide possessing a highly prized unique rheological property. In addition to being food, the material is also used in personal care products.
[230] III.2 the High Cost Zero Solar Energy, ZCOE
[231] In the above, we discussed the high cost (detrimental consequences) of the mandatory dependence on solar energy; enticed by the zero cost to ensure economic viability outdoor farming. One of the consequences is forcing conventional agronomy to succumb to accepting -0.5% and as low as 0.1% efficiency. This afforded little or no control over ¾to make further improvements beyond what has already been achieved in the last 50 years, astonishing -20 times yield improvements.
[232] Going forward, perhaps only fractional gains may be realized which are offset by higher per capita demand. The low efficiency and lack of control of outdoor solar-based and soil-based farming have lead to the requirement of enormous resources that are used inefficiently including: insatiable demand for two dimensional arable land, water, fertilizers, and pesticides.
[233] Examples 2, 3, and 4 presented in Section II highlighted the challenges associated with growing staple commodity foods indoors relying on the limited prior art understanding of ηΕ , ( sc , Eq. (2) Section I) , and why Example 1 , outdoor field farming is the only presently available viable option for growing staple food to feed the world.
[234] This viable option is for the continuous reliance on the zero cost solar energy, and its associated drawbacks or requiring fast resources that are not utilized efficiently. In addition, the outdoor farming constraint, subjects the growers other consequences; environmental and economic risks, unexpected crop losses due to microscopic pathogens, weeds, droughts, floods, and extreme unseasonable temperature variations.
[235] These collectively embody the liabilities of soil based farming. As discussed above, in connection with ultra-trace nutrients, and arsenic in particular, the health concerns associated with uncontrollable soil parameters highlight the soil liability and is the impetus behind abandoning outdoor soil-based farming and the adoption of SanSSoil methods of the present invention.
[236] III.3 Acquiring New Agronomic Controls over an Enhanced rfE .
[237] The discovery by Applicant's of the AgriPAL has been a valuable catalyst. It enabled the following:
A. Providing, for the first time, an analytical expression relating plant (organism) physiological efficiency and its direct impact on the economic viability for producing products from the plant.
B. Linking all the physiological, manufacturing, and marketing parameters to the economic sustainability in an exact unambiguous quantitative manner.
C. Enabling mathematical and quantitative accurate description to account for the role the solar energy plays, at zero cost, in plant production and in its direct coupling to the physiological efficiency, thereby elucidating, for the first time, why solar-based outdoor farming has been economically profitable.
D. The economic success of outdoor solar-based farming, as elucidated by AgriPAL, has been the main catalyst enabling realization of profitability of indoor farming artificial lighting, according to the present invention.
E. Finally, the realization that indoor farming can be profitable according to AgriPAL Eq. (2a), new agronomic control tool of through = get] , have become possible.
F. The new PGM made the physiological conversion efficiency transparent by revealing large number of parameters which can be controlled, and a plurality of means to achieve geby various combinations of controlling those physiological parameters from a large group.
G. In outdoor solar-based farming, AgriPAL is fulfilled by means of EVI = gsotf , which afford limited control, whereas in the case of indoor farming, it is fulfilled by = g^ , wherein ge affords us new levels of controls, in contrast with g∞/that has limited controls.
[238] III.4 Making Plant Efficiency η° = ge E More Transparent
[239] I now describe an improved alternative plant growth model, PGM, which has enabled Applicant to be free from the shackles of conventional agronomic practices, by avoiding the reliance on the four pillars of conventional faming: sun, soil, 2D arable land, and ample rain fall geography. This departure leads to a path of plant productivity (yield) increases of more than 10 fold. [240] As is well known, phototrophs are the organisms that carry out photon capture to acquire energy, http://en.wikipedia.org/wiki/Phototroph. Many use photosynthesis to convert carbon dioxide to organic compounds, including: carbohydrates, sugars, monosaccharide (glucose), disaccharides (sucrose), oligosaccharides, and polysaccharides (starches, cellulose), lipids, and proteins. The total biomass, BM, (living, or dead) produced by the photosynthetic conversion comprises various organic compounds, that together have an intrinsic average energy density, (energy content), sdin units of MJ/kg or kWh/kg. For example wheat biomass ranges from 3- 4kWh/kg, while lettuce and spinach biomass the range is from 0.2-0.4kWh/kg.
[241] The energy conversion efficiency, ηΕ , is the ratio of the output biomass energy content, to the total input energy during the seed-to-harvest time (growing cycle time), rsth , is described given by:
Figure imgf000040_0001
where, Y, is the output biomass yield in units of (kg I m21 year) , Psal v '& the average photon power, in W7 m2 , at photosynthetic saturation intensity from the sun, lamps, light emitting diodes, LED, or a combination thereof.
[242] Living organisms include: plants, animals, and fungi ranging in size from the unicellular micro-organisms including: algae, yeast, bacteria and cyano-bacteria, to mammoth sizes such as the 100 m high Sequoia tree and the 200 ton blue whale. I have discovered that the growth dynamics of all of these living organisms are solutions to rate equations derived from energy and mass conservation laws.
[243] They have similar growth patterns but their growth rates and substrate (resources) utilization efficiencies differ depending on the specie. The difference is stored in their genomes that evolved over a time span ranging from millions to billions of years. All organisms evolved from common ancestors with whom they share evolutionarily conserved genes that through natural selection are optimized and retrained express the production of enzymes that perform identical functions at the cellular level.
[244] My analyses and derivations (not shown here) led me to describe the growth of organism and specifically plants according to the following BM growth function:
GBM (t) = GBM (∞)(\ - e-Kt) (8)
where, (l - e~Kt) , is a composite growth function that saturates to an average maximum mass, GMB (∞) , at a rate K, both quantities (pheno types) are determined by the genome of a specie's many cultivars or varieties. The growth function is the measurable quantity that has agronomic relevance. It is referred to as composite because incorporates, and averages or aggregates, a plurality of growth rates taking place at the cellular level, even though they are not explicitly revealed in this function.
[245] Said plurality of growth rates represents the cascades of numerous enzymatic biosynthetic reactions occurring in millisecond time scale or sub millisecond. The combination of these cascaded (parallel and sequential) activities aggregates and yields the composite growth function, that is observable in seconds, minutes, hours and year time scales. The composite function does not start at t=0, instead, it begins after the seed (embryo) has adapted to the environment, germinated and emerged as a seedling.
[246] The composite growth functions of Eq. (8) may slow down and resume acceleration in periodic growth spurts, repeating nearly the same exponential behavior of Eq. (8). The derivative dGBM (t)ldt of the composite function exhibits periodic peaks and valleys. Such behavior is normal in perennial trees which stop growing in the fall and resume in the spring. Such spurts are also result from ratooning or pruning of certain trees such as sugar cane, moringa tree, and the like, and pinching off selectively shoots in order to spur the growth of branches.
[247] The organisms described by the composite growth functions are relevant and included in many aspects of the present invention. They include natural or synthetic organisms whose genotype and phenotypes are altered by recombinant bioengineering practices, well known in the art, in order to perform specific tailored functions and or deliver substances of commercial interests. These recombinant organisms of various sizes include: unicellular, multi-cellular, micro-organism and macro -organisms.
[248] The BM yield at seed-to-harvest time, rsth , is given by:
Y r,;;, |( l c λ ) (8a)
This is the rate of total mass, in kg, grown and harvested for each area cultivated per cycle time. In this case the cycle time is the same as rsth . At Krsth = 1 , 7(1) = 0.632[GMB (∞) / rsth] . In this case the crop is harvested at the maximum growth rate, in the vegetative phase, approximately before flowering. At Krsfh = 3 , 7(3) = 0.95[GMB (oo) / Tsth ] . In this case the crop is harvested after fertilization and maturity of the new seed.
[249] Depending on the species and cultivar, rsth , may range from hours, as in mass doubling time of algae, 6 weeks for Arabidopsis thaliana, or in the range or 10-20 weeks in many flowering plants of agronomic value. The short doubling time of algae and other phototrophic organisms such as wolffia, and, lemna (duckweed), have biofuel agronomic values. [250] When rsth is very long -100-150 days, as in the case of cereal production, the seasonal large temperature variations do not permit more than once a year cultivation cycle, Eq. (5 a) becomes: Y ~ [GMB (∞)/ year] . This outdoor cultivation causes a loss of macroscopic temporal efficiency of a factor 3.
[251] From Eq. (7) and Eq. (8a), the energy efficiency can expressed as:
nE = s IJ = [sdGMB (∞)(1 - )] lJ;AT TSTH (3b) and, introducing the new PGM form:
Figure imgf000042_0001
Φ = = S^S.S^S^ (4a)
i=\
Figure imgf000042_0002
[252] This naturally describes the efficiency, according to our new PGM, as the product of two separate agronomic quantities: . The latter embodies
Figure imgf000042_0003
all the physiological aspects of the organism growth at the cellular level, at millisecond, ms, time scale of even sub-ms time scale and spatial scale in the ~0.1mm-l mm range. This reveals more transparently the components of the composite growth function by relating the asymptotic mass, GMB (∞) , to the plurality of substrates or resources, St , involved in the plurality of growth reactions taking place at the cellular level representing a plurality of enzymatic biosynthetic reactions involved in growing and building the organism to a maximum value limited by
GMB (∞) -
[253] It can be shown that the absence of any one of the substrates in
Figure imgf000042_0004
GMB (∞) to vanish. This level of detail, revealed formally for the first time, will directly provide the capacity to engineer organisms, and growth systems for profitability assurance according to AgriPAL, Eq. (1).
[254] The microscopic physiological efficiency is the product of a plurality of
Figure imgf000042_0005
components, S^ S, each of which describes, sequential and parallel events involved in the growth of the organism, including: photon capture, electron excitations, charge transport, electrochemical reactions, enzymatic bio-synthetic reactions involving enzymes, and cofactors, PSI, PSII, Rubisco, and other enzymes, and such intermediates as ATP, ADP, NADP+, and NADPH. [255] The macroscopic efficiency, , deals with the macroscopic growth aspects of one or more whole organisms and involves temporal scale in the range of seconds to days and spatial scale in the range of centimeters to hectares.
[256] Each member, Sf ≡<Ti (∞) /<rimax(∞) , (S1 e S), is related to the ratio of an asymptotic substrate quantity present cr (oo) to an optimum quantity, <rimax(∞) that maximizes the efficiency, such that Sf =1, whencr (oo) = < imax(oo) . For example, if the quantity of iron available and absorbed a the organism is less than optimum, it will lead to SFe≡ aFe (oo) / < ftmax(oo) < 1 . In fact, if rFe (∞) is decreased below a threshold value, the organism will not survive, as it will be unable to carry out vital photo synthetic functions. The same outcome will result pertaining to deficiencies of the other substrates.
[257] The ratios for all components of the set, St e S, result from cascades of enzymatic biosynthesis reactions as solutions to a plurality of (Michaelis-Menten)-like kinetics equations
E + S ^ ES ^ E -i- P
kr
[258] Controlled Efficiency Gain
[259] Let us take C02 as an example. Assuming that all other parameters in the complete set
{¾ have optimum values (this is not possible in the case of uncontrolled outdoor farming, but may come close in the case of controlled indoor farming), then Scoco^ (∞) / aC0^m!iX (∞) becomes the value that limits the efficiency because the RUBISCO enzyme machinery is not utilized efficiently since the ambient (outdoor) C02 level (-400 part per million) is not optimum.
[260] FIGS. 2A-2C present experimental measurement of photosynthesis, C02 assimilation of lettuce and strawberry cultivars as a function of light intensity, PAR, for different C02 input levels ranging from 200 ppm to 500 ppm, and 80% relative humidity. It was carried out using LI- COR System 6400xt instrument. In this experiment we increased the levels to 500 ppm higher than the average ambient level of 390 ppm. Other experiments have shown that much higher levels (>10,000 ppm) of C02 levels have been assimilated by algae species.
[261] The experiment illustrates that at ambient C02, (conventional outdoor farming) and at light intensity lower than saturation intensity, the plant productivity is much reduced from the much higher optimum values.
[262] Let rn be the reduction from an optimum Sopt , then S = a Sop' . This reduction can be measured from FIGS. 2A-2C when the C02 and PAR are known, the deviation from optimum is considered a loss (lost opportunity for higher yield). From this we define the gain in efficiency as g ≡\ l α , and Sop'≡ gop' S . In the case when an enhanced efficiency
Se = ge S < gopt Sop' is prevailing, there is a corresponding enhanced gain factor g" < gopt .
This is an examples degree of control over the gain factors afforded by indoor culture.
[263] Similar gain factors can be realized by the optimization of the other substrates and environmental and other relevant photo synthetic parameters. This is one of the key aspects of the present invention in connection with indoor sun-less, and soil-less farming. More specifically the realization of gain factors that enter into AgriPAL Eqs. (6) (6a), (6b) that ensure profitability for staple commodities such as food and biofuel.
[264] From the above, we recognize that for each member of the set, St e S, there exists an enhanced member in the set Se Se , having the relation Se = geS and the opportunity for maximization of geto reach gopl under optimum conditions.
[265] This general conclusion is equally applicable to any member in St : Cu, Mo, K, or any other essential element as shown below.
[266] Note that one key aspect of the transparent inclusion in Eqs. (4), (4a), (4b) of every nutrients, primary or secondary, main substrates, environmental factors, genetic factors and energy inputs, is the democratization of value (equal importance) of each of these parameters .
The absence of any one, will render the whole to a much lower value (size, color, taste, aroma, nutrition, etc), or even death of the organism. For instance, no matter how small the copper trace may be, in certain plants, its absence will render the organism useless.
[267] Equally important, an overdose above an optimum value of a certain trace element, may be toxic, or may be antagonistic to the uptake of other elements. For this reason each component in the set Se = geS has an optimum range: a minimum level and a maximum level, which lead to the highest productivity. Below the minimum value of a certain component, growth may either be prevented, or substantially reduced. Above the maximum value, may limit growth to a maximum, saturating or asymptotic value, or may be considered a toxic overdose that has adverse effect on the viability of the whole plant.
[268] In addition to the primary, secondary and traces nutrients that need to be controlled, there are ultra-trace nutrients the levels of which vary locally from one soil geography to another. The benefits of these nutrients to the plants are not well established. However, humans may ingest plants laced with levels of arsenic that are harmful to human health. It is established that ultra- trace nutrients have certain roles in plant growth and potential impact on humans and their ultra nutrients: [269] Recently, there has been concern regarding the quantity of rice consumed by Americans because of concerns over arsenic, and the FDA is investigating the matter. Researchers have found geographical distinctions in arsenic levels, with white rice grown in Arkansas, Louisiana, Missouri, and Texas, containing higher levels than rice samples from other parts of the country. Those four states account for 76 percent of domestic rice produced. This alarming finding has spurred the US Congress to action:
[270] The health concerns associated with uncontrollable soil parameters is yet another proof that soil is a liability and the driving force behind abandoning outdoor soil based farming and the adoption of SanSSoil methods of the present invention.
[271] A second aspect of the transparent inclusion is related to efficiency gain control: Se = geS . The absence of any key members means death, the presence of only a fraction of the optimum level means less than optimum yield, longer maturity time, stunted growth, etc. One the other hand, much higher level (over dose) of minerals above the optimum, leads to toxicity, death lower yields or consumer toxicity.
[272] One of the key aspects of the present invention is the benefit of the gain control through Se = geS , enabled by the controlled, enclosed environment of indoor farming. This privilege, in not available in the case of outdoor solar-based farming, where, the low S , continues to be in effect. Soil analysis is required in order to determine what nutritional supplements to add to the soil. Since soils differ even in adjacent regions it is not possible to purchase nutritional supplement products that remedy exactly the deficiency of all soils.
[273] The lack of control of soil components, toxicity to plants and humans, the presence of pests, the uncontrolled exposure to temperature extremes, and other adverse environmental and climactic, together embody the soil liability.
[274] The Microscopic Physiological Efficiency Components
[275] Eq. (4a) separates the set S into related groups. The following is a non limiting exemplary grouping scheme. Other schemes may prove advantageous and may incorporate other components physiological and or physical parameters known to influence growth and yield. Few examples have been given to illustrate the roles of certain parameters; leaving out of the discussion other parameters should not limit the premises based on which the inventive embodiments are built. The following grouping schemes are set forth:
1. Sm = SC0^SH^0S0^ : The main ingredients for building organism biomass: carbon dioxide, C02
, water, H20 , and oxygen, 02 which together account for ~ 99% of the organism weight. It comprises biosynthesized substances that include: hydrocarbons, sugars, starch and polysaccharides. 2. Sj = SNSPSK : The primary nutrients made are of nitrogen, phosphors and potassium compounds (generalized as NPK). They are responsible for life giving bio-molecules, including: amino acids, DNA, RNA, ATP, ADP, NADP, polypeptides, phospholipids among others.
3. Sn = SsSCaSMgSMn SCu : These are the secondary nutrients, Ca, Mg, S, and the trace micronutrients, B, CI, Cu, Fe, Mn, Mo, Zn, among others, that are required in parts per million quantities, PPM. They are essential in spite of their relatively small (trace) quantities for the construction of key enzymes responsible for the regulation of growth, reproduction, signaling, timing, and storage.10
[276] The deficiency in any of the above substrates, i. e. , St = £,- (∞)/ Sjmsil (∞) , lower the overall efficiency of the whole organism. If any one of these substrates is absent, clearly, the efficiency is zero and the embryo dies. On the other hand, the existence of an overdose of these the trace elements or undesirable elements (Pb, As, Se, Cr, and others) that are not required by a particular specie, will have adverse phyto toxicity impact on the plant, and the consumers of the plant.11
[277] 4. SBr : This efficiency component pertains to the genotype and the traits (phenotype) of the organism. In conventional soil-based, solar-based outdoor farming, SBr , is constrained by the local geography that is characterized by specific resource availability including: latitude, temperature, water, intensity of solar illumination, temporal availability of illumination (day lengths, season, ) , salinity, pH, and the local specific trace quantities of mineral. Certain locations are suitable for the high yield growth of specific cultivars while they cannot support others.
[278] As is well known in the art, breeding is an expensive enterprise that is constrained to produce seeds of cultivars that can maximize their growth in the maximum geographical locations as possible, to ensure profitability of the breeding enterprise. It is costly custom breed a plurality of cultivars optimized to cover many small geographical regions. The consequence of this, is the breeding of cultivars with a compromised set of traits, in other words, the efficiency SBr is less than ideal.
[279] One key aspect of the present invention is the decoupling of indoor faming from the conventional soil constraints, which we also refer to as SanSSoil farming. More specifically, the present invention enables the elimination of the constraints of breeding cultivar for different
The following references teaching more details related to the key roles nutrients play: BR Global, LLC, "Micro Nutrients And Secondary Nutrients," circa 2008 (http://\¥ww.brglimitedxom/do\^riload MicroNutrientInfo.pdf) , North Country Organics, Trace Elements, circa 2009 (http://www.norganicsxom/applications/trace.pdf)
11 The following references teach more details about the impact of control of nutrient quantities: Shabala, "Physiological and cellular aspects of phytotoxicity tolerance in plants: the role of membrane transporters and implications for crop breeding for waterlogging tolerance," New Phytologist (2010), pages 1-10; Baumgarten et al., "Phytotoxicity (Plant tolerance)," Agency for Health and Food Safety, Vienna, April 2004, pages 1-36. local geographies. The controlled enclosed farming according to the present invention enables the growth of all organisms in any geographical location with the highest yield possible provided one adheres to a uniform set of rules and growth parameters. This is never possible in outdoor farming.
[280] The decoupling from the soil, leads to an optimized cultivars with and enhanced Se = ge S , with ge >1 controlled by an intelligent system controller that dispenses the correct amount of nutrients, the correct pH and the optimum environmental conditions for maximum yield.
[281] According to the Mudler's Chart, and recent discoveries, the root uptake of a one or more nutrients can be antagonistic causing the inhibition (limitation) of uptake of other nutrients as a result of altering the pH and electrochemical potentials. In other situations, the presence of one or more nutrients has a simulative effect of enhancing the uptake of others. Indoor SanSSoil farming has an unprecedented opportunity to control the nutrient uptakes to enhance the uptake, eliminate competition, overdose and as a result will increase the overall gain factor g .
[282] One aspect of the present invention is to use a combination of foliar feeding and root feeding in parallel or sequentially to beneficially enhance the uptake of nutrients. Another aspect of the invention is to sequentially pulsing groups of nutrients, i.e., applying a first short duration burst of a first group of nutrients, followed by a second short duration burst of a second group of nutrients, and the sequence is repeated as needed.
[283] These traits of plants (organisms) had evolved over a long time before the interference of humans. Humans have practiced breeding methods over thousands of years since the domestication of relevant food crops. They later accelerated and perfected breeding methodologies guided by Mendelian laws. This was a key contributor to yield increases of more than 10 fold and the Green revolution of the 1960's. Since 1990, recombinant DNA bioengineering technologies have produced varieties of GMO's that increase the plant productivity, and pest resistance.
[284] There continues to be the opportunity to achieve enhanced efficiency and yield by means of modern recombinant bio-engineering and modern breeding methods to increase the efficiency though Se = ge B S b . Permanent or transient genetic transformation of plants can regulate and optimize all aspects of their growth depending on the beneficial new genetic traits that alter enzymatic bio-reactions discussed above.
[285] 5. Senv = SsmlSpHSTSweatherSpest : The efficiency components combine the effects of the environments on the organism health and agronomic profitability. This is one key aspect of the reliance on the zero cost of solar energy. One of its main constraints is the requirement of cultivating outdoors on large 2D areas subjected to many adverse environmental impacts. In addition to the bio-chemical aspects of the soil discussed above, the soil serves many purposes including: mechanical support of the root, nitrogen fixing, supplying water and oxygen, supplies minerals that affect the pH.
[286] The combination SsoUSpH optimally should be close to 1 any departure from optimum will be considered a loss. This can be reversed as gain, acceding to aspects of the invention by means of controlled SanSSoil indoor culture methods. The seasonal and daily temperatures and weather conditions contribute to losses through STSweather have significant predictable and unpredictable roles that impact the farmers' activities and profitability. The unpredictable temperature and weather conditions pose significant uncontrollable risk of plant productivity reductions. Too much or too little rain, unseasonable high or low temperature at unpredictable times, all pose risks and enter the efficiency equations. Finally, Spest, measures how effective the farmer is able to avoid or minimize the impact of plant diseases, weeds, birds, and other pests.
[287] 6. S hoton = SAStSsp This group deals with photon energy resource that is the driver of photosynthesis energy conversion and food production.
[288] 6.1 The spectral efficiency: SA : It is well known that the solar radiation spectrum is quite broad, spanning the range from the ultra-violet to the infra-red. The plants however, absorb only a narrow portion of that spectrum, in the visible range, concentrated in two prominent chlorophyll absorption peaks near 400 nm and 680 nm. The region in between, is the green region that is not absorbed, and endows all plant leaves with that color. The absorbed radiation is referred to in the plant science literature as the Photo-synthetically Active Radiation, PAR.
[289] The spectral efficiency SA is approximately 0.487, which represents the energy portion,
PAR relative to the total energy of the solar radiation spectrum. Plants have evolved to maximize growth by absorbing the blue and the red components. However, in our PGM, we eliminate the need for the sun radiation, to enable us to control the optimum photon density and energy to achieve the maximum growth rate and energy utilization efficiency. This allows us to obtain SA =\, achieving a factor of 2 gain, by using a narrow LED wavelength near 650 nm or any where between 650 nm and 680 nm. LED's in this range have the advantages of being very efficient and at lowest cost.
[290] 6.2 The Microscopic Spatial Efficiency: S : Using modern microscopy, it has become well known that plastids are organelles that comprise the machinery necessary for converting light energy and C02 into hydrocarbons. Chloroplasts are the green plastids that comprise chlorophyll pigments that are responsible for absorbing light. However, while chlorophyll density in plant cells is very high, it does not occupy the entire plant cell volume. This enables us to measure accurately, the spatial occupancy efficiency, S of the light harvesting antennas.
[291] It can be shown that the value of S approaches -0.5. According to one aspect of the present invention, the enclosed indoor farming enables all the light to remain in the system by means of recycling (reflecting) from one organism to another. This is made possible by means of ensuring that light is absorbed within the system the components of which are made substantially non absorbing. In this case S may approach 1, thereby garnering a relative gain in efficiency of a factor of ~2.
[292] Indoor farming, therefore, enables the realization of a gain of 4 from the maximizing both Ssp and SA .
[293] 6.3. The Microscopic Temporal Efficiency: St : In formulating the new PGM, Applicant discovered the microscopic temporal factor St in the millisecond time scale, that represents the temporal mismatch between the enzymatic kinetics of Photo System II, and Photo System I , the fast light reaction, on the one hand, and the slow enzymatic Calvin reaction (dark reaction) responsible for assimilating C02 and producing glucose. Applicant discovered that this temporal mismatches factor is between 5 and 10 that previously had been unaccounted for as photosynthetic loss. This temporal loss factor ^ is identified, without being limited by theory, as the ratio St « -^- « 0.2 - 0.1. This has been measured experimentally by Applicant by means on
^ 'dark
inventive pulse light photosynthesis experiments that varied the pulsed light frequency from 10 Hz to 500 Hz, and pulse duty cycles from 100% (CW) down to 0.1% . These experiments are discussed below, with the aid of FIGS. 2E-2H.
[294] Conducting a series of experiments varying plant species, (several lettuce varieties, broccoli, geranium, strawberry) Applicant confirmed the possibility of evolutionarily conserved nature of -^- « 0.2 - 0.1 , and succeeded conceiving inventive features according to the present
^ 'dark
invention that increase the gain of the efficiency by factors of 5-10 in these plants.
[295] FIGS. 2 A to 2H provide exemplary experimental illustrations of the ability to control the growth and gain parameters of various species obtained by Applicant. Li-COR 7400XT photosynthetic instrument system has been used to determine the photosynthetic responses to various parameters including: temperature, humidity, C02, oxygen, light intensity (PAR), pulsed illumination at various frequencies, and duty cycles. [296] FIGS. 2A-2C measures the responses of two lettuce cultivars and strawberry, as light intensity and C02 levels are varied. This confirms the well known saturation levels that are determined and limited by the microscopic cellular enzymatic biochemical reactions discussed above. The measurements confirm one of the premises of this invention that in indoor farming increases in C02 and light intensity to levels higher than conventionally available for outdoor farming, results in higher plant productivity. This validates the conclusion that plants are underutilized in the outdoors, i.e., they have much higher capacity that practically realizable due to the sun and soil constraints.
[297] In outdoor farming, the temperature may vary widely daily and seasonally from -20 to 40 degrees Celsius limiting the control over plant productivity. On the other hand, FIG. 2D illustrates the fine temperature control available to indoor farming. In this example the graph shows the measurable difference in response to a 2 degrees temperature change. This validates the ability to hold the temperature fixed at a value that achieves maximum productivity, and gain factor for particular specie.
[298] In our PGM the temporal gain component gt is incorporated, revealing transparently, the enzymatic dynamical contribution to plant growth efficiency that has been omitted in prior model in Eq. (1). FIGS. 2E-2H is experimental illustrations and validation of temporal control according to the present invention. FIG. 2E shows the response of a rose to applied pulsed illumination of LED at 860 nm, 50% duty cycle, as the period is varied from is varied from 5 millisecond to 200 millisecond. The response drops off from 6 to 3 at 100 ms (-10 Hz) which reveals the speed of the Calvin, dark reaction. This behavior is analogous to the cut-off frequency of high pass filters in we known in the electronics circuits art.
[299] At the high end of the frequency spectrum, the plant behaves as a low pass filter, giving a photosynthesis response only below frequencies in range of 200-300 Hz. The LED source at 860 nm is designed to deliver a train of high intensity light pulses of width rpulse and period τ riod allowing the duty cycle in percent: dc≡ [i00(rpulse I rperiod)] to vary from 100% to 0.1 %.
[300] FIG. 2F is an exemplary graph of Winter Destiny Lettuce photosynthesis response to duty cycle fro defect frequencies (1/ τ riod). What is striking is the revelation that at 200 Hz, the response at 50% is the same as for 20%. This is a measure of temporal losses which prior art model could not account for. According to the present invention, this loss is reversed as gt~5, as can be measured from the slope as a means for controlling the temporal parameters of the light source. This experiment also enables the measurement of the low pass cut off frequency and the speed limits of the light harvesting systems PS I & PS II. Note also that the gain is reduced as the frequency is decreased, showing the speed limit of the Calvin dark reaction of C02 assimilation.
[301] In FIG. 2G, the frequency is kept fixed at 200 Hz, and the duty cycle is varied for 5 lettuce varieties, indicating the same general behavior and showing temporal gain factors gt ranging from ~4 to 5. When humidity and C02 levels were varied, the lettuce variety Paris revealed a gain of ~9 is possible. This temporal behavior, trait, has so far been repeated in all species tested, strawberry, broccoli, geranium, giving gains gt ranging from 3 to almost 10. These gains are related to the speed mismatch between light reaction and the dark reaction and they are correlated to the ratio ij dark I τΗ Μ) , and it the measure of efficiency losses which prior art could not account as discussed above.
[302] This temporal seems to be evolutionarily conserved and is exhibited by all plant. Other investigators of plant response to pulsed illuminations have not measured gain.12: These previous investigations either used light intensities well below the saturating intensity, where the efficiency is very high or have not been able to correlated or anticipate the temporal mismatch between the slow dark reaction and the fast light reaction. The gains measured according to FIGS. 2F-2G are obtained by adjusting the intensity to just below the saturating values, where photosynthesis to the highest value, and any losses should be revealed there. It is known in the art that increasing the intensity well above the saturating level leads to substantial photorespiration losses. The present invention maintains the intensity just below that level for achieve two benefit: maximization of the temporal gain factor and the avoidance of photorespiration losses.
[303] Applicant's success in measuring the temporal gain, at least in part, validates model, PGM. It also shows that the temporal gain control is at least one vehicle that is now available, reliably, according to the present application, to increase EVI until profitability of indoor plant production is achieved according to AgriPAL.
[304] The following are several additional examples of the degrees of control, afforded by the present invention, of specific groups of gain factors and their practically realizable values:
[305] Example 1 : gphoton = gAgtgsp> using this group, with pulse illumination farming, we can achieve a gains of :
(S ~~ 2)(gt— 3)(gsp— 2) $ photon nr
12 Tennessen et al., "Efficiency of photosynthesis in continuous and pulsed light emitting diode irradiation," Photosynthesis Research (1995) 44:261-269 ; Mori et al. US 20040109302 Al , "Method of cultivating plant and illuminator for cultivating plant." (§λ = 2)(g, = 10)(g^ = 2) = 40x¾¾oto„ [306] Example 2: G2 = gAgspGspGf , using this group in three dimensional multilayer farming, it is possible to achieve a gain:
(¾ = 2)(g„ = 2)(G„ = 10)(G/ = 2) 0x¾¾ or = 2)(g„ = 2)(G„ = 30)(G/ = 4) =480x¾½
[307] Example 3: combining the above options 1 and 2 to achieve gains ranging from 10 to 1000. If solar gain is also added in the case, gains exceeding several 1000 will be possible.
[308] Example 4. g gspgmgenv— g g Spgmg soilS pHSrSweatherS pest
[309] Example 5: g gspgm = gAgspgCOlgHlogo1
[310] Other options will be described in connection with the embodiments that select groups
n
and combination of groups selected from the complete portfolio (G^GiG/)(]^[g!) . The above examples are not intended to be limiting. The methods of this invention include the steps of first determining the components, η = ξφ = , then determining the gain values selected from
Figure imgf000052_0001
= = g^G^ ητ in order to engineer a design that achieves the optimum index EVJ"≡ rfE≡ g^E that must satisfy the AgriPAL condition.
[311] From Table 1 values of outdoor efficiencies 0.001 and 0.01 are not uncommon. Therefore, in controlled indoor environment, according aspects of the present invention, achieving gains, ge of 100-1000 are not unrealistic. However, laws of energy and mass conservation are strictly adhered to which restrict g^E≡EVIe to be less than one. There are many ways of increasing geto large values, but must always reach a limiting value (asymptote) such that the product ge¾≡ EVJ" may approach 1 but never exceeds 1. This would be enough to satisfy the AgriPAL condition of economic viability for all plants and other photosynthetic organisms grown indoors, including algae strains and cyano-bacteria for biofuel production. Any increases in RCR such it exceeds 2, ensures economic viability for biofuel and staple food products. One the other hand other plant based products are always profitable since most of them have RCR> 5.
[312] For outdoor faming based on solar illumination, there may be the possibility that gsotfE = EVI can exceed 1, without violating energy conservation law. This, for thousands of year, has ensured profitability through gsol ERCR > 1. This possibility stems from the fact that the cost of solar energy is zero, and over time we accumulate (store) energy in the form biomass chemical bonds, i.e., there exists enough solar energy to compensate of the inefficiencies of plants, and enough net energy is accumulated. It is possible that at least one seed germinates in the field, leading to growth to maturity with substantially minimum human effort or minimum other energy applied, such that g∞/¾ is larger than 1. It may even be larger than 10. In the case of sugarcane, g∞/¾ between 25 and 50 has been achieved. This is possible when sother in the denominator of gsol = ssol I sother is small or even vanishingly small, once again it is possible with sugarcane especially when some of its output energy is fed back to the field operation.
[313] The Macroscopic Efficiency Components
[314] The microscopic, physiological yield components Eq. (4a) described in detail above reveals efficiency components, and parameters of gain and loss that has not been previously and transparently investigated. Equation (4b) describes additional macroscopic components, affecting the overall yield, that also had not previously been explicitly identified or described by plant scientists and agronomists. Their relevance is related to the economic viability and profitability according to AgriPAL. This may be unintentional omission for outdoor soil-based, sun based farming, because the growers and agronomist have had no or limited control over the growth condition as a result of their reliance of solar energy at zero cost.
[315] On the other hand, our PGM removed the sun and soil as constraints thereby enabling a new focus on new loss mechanisms and how they can be exploited for indoor farming according the present invention by inventive means to reverse the losses, turning them into gain components ofge .
[316] Each of the macroscopic efficiency components in the group: ξ = ξ t f is now described in turn.
[317] 1. The Macroscopic Temporal Efficiency: ξί
[318] The microscopic temporal efficiency ^ , described above, is the embodiment of the enzymatic kinetic speed of responses of various reactions that take place in millisecond time scale. The macroscopic temporal efficiency, ξί , on the other hand, involves the life cycle time trajectory, (seed to harvest time rsth ) of the organism as a whole. For high plants, the germination, vegetative growth (exponential), flowering, pollination, fertilization, and fruit (seed) ripening, all take place in a time scale of weeks and months. The model plant Arabidopsis Thaliana needs about 6 weeks, while soybean, wheat and rice need 14 to 20 weeks. [319] It is well known that the cycle time is influenced by many factors including environmental (soil, pathogens, weed, temperature, water, illumination hours per day), agronomic practices, and genetic, and nutritional. Applicant recognized that conventional prior art outdoor farming methods, crucially dependant on the zero cost solar energy, are wasteful of time and do not have flexibility to improve the efficiency ξί .
[320] Let us take the example of wheat, corn, or soybean seeds that are planted in the fall, e.g., October. 6 months will elapse before seedlings emerge. The emergence may be one month early or one month late deepening on the weather. Harvesting may be in July or August. The efficiency ξί is therefore recognized here as the time utilization reaction: ξι≡ τ sth(days) 1 65days . In this example: ξ( = \20/365days= 0.329. Due to weather uncertainty, and the various other factors, such as the quality of the seed, ξί may be 0.27 or may even be as low as 0.24.
[321] Because we concluded that indoor farming for staple food is out of the question, the potential for a factor of 3 or more temporal efficiency is not realizable with prior art outdoor farming metho ds .
[322] One aspect of the present invention is teaching systems and methods that substantially regain the temporal efficiency lost outdoor environments for growing staple food, by using, instead, inventive architectures for indoor environment agriculture endows with the capability to enable energy efficiency ηΕ to increase by factors ranging from 5x to 50x or even higher. This will allow the number of crops harvested per year to be \ /ξ( > 3 , which is the increase of annual yield per hectare.
[323] Yet another aspect of the present invention is allowing the possibility of increasing the temporal efficiency by means compressing rsth by another factor of nt . This is a temporal compression of the plant seed to harvest cycle time by nt , so that the annual yield increases by XI ξί = 6 nt l Tsth) . This temporal efficiency enhancement according to some aspects of the invention is in the range of 3-10, and more preferably from 3-20, and even more preferably from 20 to 50. Yet in other embodiments, the enhancement will exceed 50.
[324] This macroscopic temporal enhancement in addition to other efficiency increases garnered from the components of, <j)micro , according to embodiments in the present invention have a multiplicative factor to give a large overall energy efficiency enhancement, rfE = g ]E in excess of 50 time or even in excess of 100. It is these composite enhancements that enable the indoor farming of staple foods and other foods profitably. The ability to profitably cultivate and harvest many foods according to the profitability assurance, AgriPAL described in Eq. (1) can be shown not possible using prior art indoor farming.
[325] 2-The Macroscopic Spatial Efficiency: ξ
[326] Another agronomic loss factor that is recognized by plant scientists and agronomist is the spatial losses, or low space utilization efficiency ξ . While it is recognized, virtually no efforts have been taught by prior art related to how to increase ξ . The main reason is the reliance on the zero cost of solar energy, thereby succumbing to the inability to deal with and control the low resource utilization efficiencies, comprehensively described by Eqs. (4), (4a) and (4b).
[327] Once again we look at exemplary situation of cultivating soybean, wheat, or corn in such regions as Nebraska, Kansas or Iowa. Seeds are planted in October and the seedling will emerge in March or April depending on the weather. During that period, the land as an asset is not utilized for anything else. The is factored in the low utilization efficiency ξ After the seedlings emerge and begin their vegetative growth phase and before the full canopy forms, the space between the plants is not filled which is manifest itself, once again in low ξ .
[328] Above the soil and beyond the plant height, 1-3 meters, the three dimensional space is not utilized for any purpose. Again, this loss is reflected in . At the time, the space is not utilized efficiently, solar energy is squandered and is accounted for by means of the temporal efficiency, ξί , discussed above.
[329] Another aspect of the present invention, therefore, is the teaching of an inventive three dimensional agriculture, multi-layer or multi-level farming, that increases spatial utilization efficiency by at least a factor of 10. By further increasing the number of vertical layers to about 100, the volumetric yield is increased by this number.
[330] In one preferred embodiment, we describe an inventive integrally made plant growing module, or an integrally made plant growing element, or growing structure, a plurality of which are assembled into a three dimensional growing structures that feature ultra-space compactness, spatial compression, as manifested by the growing organisms sharing all the space and nutrients in unique manners.
[331] The Macroscopic Farmer Efficiency:
[332] In agronomically advanced regions, conventional outdoor field farming, to be economically viable, requires a minimum average farm size to be about 250 hectares and benefits from advanced farming tools to enhance yield and reduce labor cost. These tools aid in performing several functions including: soil preparation, planting, irrigation, application of pest controls and harvesting. [333] In addition to spatial constraints imposed by these tools to function effectively, the farmer makes certain decisions as to what to plant, what nutrients to buy, from what source, and the quantities and timing of applying these resources, and timing decisions to carry out the farming activities. These collectively are reflected in the farmer's efficiency parameter^ , which is considered a loss since the decisions and their timing are never perfect (human errors) and depend on certain unpredictability of the weather conditions.
[334] This is an opportunity for enclosed controlled environmental indoor farming, according to aspects of the present invention, to achieve a gain factor that enhances ξί , resulting from more accurate unambiguous optimized decisions timing, and optimized dispensing of nutrients.
[335] This emphasis on many aspects of %macro = ■> presented herein, is to our knowledge, done for the first time by Applicant pursuant to the present invention. Large gains ranging from 10 to 100, and may even exceed 100, will be shown to result from the inventive features of the present invention.
[336] III.5 Plurality of PGM Efficiency Control Options to Satisfy AgriPAL
[337] As discussed above, the conventional outdoor field farming dependence on the sun and soil deprived agronomist from having access to many of the physiological and physical loss mechanisms embodied in the PGM descriptions given by Eq. (4) repeated below.
Figure imgf000056_0001
^Π^ =νΑ¾^ (4«)
=1
m
[338] Consequently, Agronomists have had no ability to control these parameters.
[339] Thanks to AgriPAL condition in Eqs. (1), (6) a clue as to how and why conventional farming achieved economic viability was revealed by means of the outdoor economic viability index: EVI ≡gmflE .
[340] AgriPAL has also been the catalysis behind the ability to make sun-less, soilless indoor farming viability for staple crops. Much higher profit margins can also be achieved for the production of non staple crops, by requiring the need for an indoor economic viability index: EVIe≡rfE≡geJ E which is the object of many embodiments of this inventions and related copending applications. The transparency of the energy conversion efficiency components gained from the PGM enabled the realization of several gain components EVV≡rfE≡ g ]E that satisfies AgriPAL thus:
Figure imgf000057_0001
ξ° = Οξξ
n n
i=l i=l i=l
Figure imgf000057_0002
n
i=\
Figure imgf000057_0003
Si ~ SNSPSK
SlI— SsScaSMgSMn
Figure imgf000057_0004
Senv S soilS pH ST S weatherS pest
' S StSsp
ge = g G, (GspGtGf )(Ylgl)
i=\
[341] Gain Control Options:
[342] It has now become possible to examine the complete portfolio of gain parameters given n
by (G ^Xj^ ;) , to provide engineered solutions, options, designed and optimized to achieve desirable indoor sun-less, soilless, SanSSoil farming. Such a control has heretofore not been possible.
[343] One aspect of the present invention is an integrally formed growing element called SansSoil Growing Element, SGE. It is self-sufficient in the sense that it integrates many essential functions for growth in the smallest space and a lowest cost. One distinguishing feature is the direct delivery of nutrients to the plant root from top down, instead of spaying the root from the bottom up. The integral multifunction constructs of the SGE's enable their connection into strings and 3D network of strings that will save space and resources by sharing resources. The inventive aspects of the SGE are key reason for cost reduction to enable staple economical food farming satisfying AgriPAL condition even when = ~ 1. The construction and functions
COE
of the SGE and their interconnection into networks of stings is the main object of the present invention. In certain embodiments these SGEs are interconnected in a manner that permits continuous flow agriculture.
[344] The network of strings, forming multi-layer 3D systems, is further distinguished from prior art by the inventive permeability feature of said multi-layers. Layer permeability is defined as the ability to pass through to neighboring layers, light (transparency) and nutrients, received from other neighboring layers. In addition, the shoots and roots of one layer may pass through neighboring layers. This enables the roots of one layer to share the space of the shoots of a neighboring layer below it. The end result is high utilization efficiency of the vertical space by compressing the interlayer spacing needed. The light transparency feature reduces the number of artificial illumination sources as well as the energy consumption.
[345] Described above is a transformational new paradigm for agriculture that can be realized to solve the problems facing humanity and achieve food and plant based energy security. One key feature of the new paradigm is the understanding the profitability conditions of farming. This has been accomplished by the formulation of Agriculture Profitability Assurance Law, AgriPAL, Eq. (1):
F ROE
//.·· ( ' ) v„.■ < ' · / ( D
ε other ^OL
AgriPAL enables an enterprise to predict profitability of plant growing systems, to prices, and to identify efficiency bottlenecks.
ε,.
[346] The economic viability index, EVI, is defined as: EVI≡ ηΕ ( "∞ ) = ¾ ∞/ar . This links other
for the first time the economic parameters of farming, profit, p, fixed cost, f, variable cost, v, to the physiological parameters of organisms (plants, algae, other phototrophs) , energy conversion efficiency, ηΕ , including a gain factor, gsolar = (—— ) , wherein, ssol , is the solar
^ other
energy consumed per cycle and, sother , all other energies consumed.
[347] An enhanced EVI is derived from the new Plant Growth Model, PGM, also described above, is given by: EVI"≡rfE≡ g^E . This increases the efficiency by yet another gain factor, ge, which can be 10-100, achieved by means of controlling and optimizing physiological growth parameters as well maximizing the temporal and spatial resource utilization efficiencies.
[348] Aspects of AgriPAL are further described that deal with maximizing space utilization efficiencies, which include three dimensional, 3D, soil-less (SanSSoil) plant growing structures and subsystems to sustain growth. More specifically, the aspects that reduce the cost of said structures and subsystems which lead to the minimization of the parameter f in Eq. (1). Even more specifically, the increase of g^E which is a function of the n, the number of vertical layers in 3D farming systems wherein the yield is measured in units of ton/hectare-meter, or ton/m3, or kg/m3.
[349] In certain embodiments in the present application, plants are grown in 3D space that is limitless. More specifically, 3D space including, growing plants in 3D edifices, structures, or towers of heights, ranging from 10 meter to 100 meters, and even more preferably tower heights beyond 100 meter perhaps approaching 500 meter or even 1000 meter. Building having heights exceeding 500 m already exist. It is also known that making wind turbine tower as high 150 m is economically feasible.
[350] In certain embodiments in the present application, systems and methods are disclosed that enable the increase in productivity using the system of Traveling Seed Amplifier, TSA, to enable continuous flow farming or production of material products, MP, including PMP, and CMP, synchronous planting and harvesting, and novel systems and methods to compress vertical space and time required for MP growth.
[351] FIG. 3 A is an exemplary depiction of an indoor SansSoil farming system 100, comprising a SansSoil sheltered and protected controlled environment 101 and a control subsystem 102. The SansSoil sheltered and protected controlled environment 101 is designed to be substantially impermeable to pests, and undesired gases, liquids, particulates, and other foreign objects. Preferably said protected environment is well insulated and protected from outside temperature swings in order to maintain a desired temperature that is most suitable for growth and results in maximum productivity.
[352] It will be appreciated that the depiction in FIG. 3A including the master controller, power supply, species/variety specific growth controller, nutrient dispenser controller and associated nutrients and environmental control, power supply, and illumination power conditioner and distribution apply to several embodiments herein and need not be repeated.
[353] In certain situations, solar radiation may augment artificial light for photosynthetic growth. In this case, the SansSoil environment 101 may be equipped with filters to filter out unwanted solar wavelengths including ultra-violet, infra-red and certain visible wavelengths. [354] The hybrid growth method based on the combination of artificial lighting, preferably LED, with selected solar wavelengths, will enable the maximization of gegsoiar , viability index and the profit margins established through meeting the AgriPAL conditions.
[355] The SansSoil environment also comprises structures for handling, planting seed/seedling in the input port, 105, also referred in certain embodiments to as the planting port. The mature plant product is harvested at the output port, the harvesting port 104. Said structures are preferably designed to incorporate appropriate sealing structures such as load locks in order to maintain sterile or near sterile conditions. Structures to achieve impermeability and sterility of SansSoil edifices are well known to persons skilled in the art. Internally, the SansSoil environment 101 houses a plurality of SansSoil material product, MP, growth layers 103 disposed in a three dimensional space. In certain embodiments the SansSoil MP layers are made from structures and materials that are optically transparent, thereby enabling the layers to share and recycle unabsorbed light, and thus increasing the light energy utilization efficiency.
[356] The control subsystem 102 is programmed to control all aspects of growth physiology to
n
achieve economic viability by ensuring that EVV = gJ]E = (Gs?)G(G/)(]_[g!.)¾ approaches or exceeds 1 in order for AgriPAL condition to be satisfied. Each gain parameter in the portfolio has an optimum range that gives the maximum value. This is adjusted by the subsystem 102 for each species. The upper and lower limits of this range are determined experimentally in optimized environmental parameters.
[357] In some situations, a group comprising more than one interacting parameters can be adjusted and optimized together. For example, adjusting the carbon dioxide to an optimum value limited by the dark reaction enzyme density requires adjusting the light level until it is limited by the light reaction enzyme density. The steps of optimization are aided by appropriate sensors which communicate with the controller values that require adjustments.
[358] The Integral SansSoil Growth Element
[359] Each layer 103 within the SansSoil environment 101, is so designed to sustain the growth of plants or organisms in integrally made SansSoil growth elements (modules), SGE 1, described further in FIGS 3B-3K, and FIGS. 4A-4P. The layers 103 and the plurality of SGE's are spaced in such a manner that optimizes the space utilization efficiency Gsp .
[360] Each SGE 1, comprises integrally made structure la, lb which houses the plant 2, the shoot 2s, and the root 2r, and connected to a nutrient sources 3, 3a. The nutrients drip or spray downward on the root in the cup like substructure. One key aspect of the present invention is to combine this method of feeding, with foliar feeding, well known in the art. This is accomplished by means of fogging subsystem (or mist), which preferably supplies micron scale fluid particles (droplets) that are absorbed directly by the plant leaves, by-passing root uptake. Each SGE 1, optionally and integrally comprises a light source 4, and a sensor 5.
[361] It is also possible to have two fogging systems, one for supplying one set (a first set) of nutrients to the root and a second supplying different nutrient set to the leaves. In addition to providing more than one feeding sources, it is contemplated that in certain situations, said sources may be applied sequentially, or in a temporally pulsed manner with adjustable periods and duration.
[362] This inventive feature is unique to indoor farming, according to the present invention, because it affords a new degree of freedom for the subsystem 102 to control the components of gain factor ge , through optimization of the operating range of each component. This is especially advantageous when two sets of nutrients are antagonistic to each other, competing to prevent the optimum pH to establish for maximum beneficial uptake.
[363] FIG. 3B shows that in each of layers 103a, 103b, and 103b, the SGE's (FIG. 2C) are connected in strings 106, that are connected to nutrients sources delivered to each SGE site. In the first spatial coordinate, x, the SGE repeat at period px, 107a, while the strings repeat in the second coordinate, y, at a period py, 107b. In the third spatial coordinate,, z, the layers repeat at period pz, 107c. The dashed lines 108 depict columns of SGEs in there respective layers. The total number of plants in the 3D system, N3D = (Nxpx)(Nypy)(Nzpz) , determines the overall 3D productivity of the system 100.
[364] The illumination sources lh, lj and auxiliary sensors, lg, or other resource, are disposed in any orientation relative to the three spatial coordinates, FIGS 3C-3E.
[365] As shown in FIG. 3F, a plurality of SGEs are connected as a linear string 1 11 a, which is connected to one or more sources 3. The connection structures are so designed to deliver, with high conductivity, nutrients to each site 1. Preferably, these structures are designed for quick connection to the SGE, enabling rapid, inexpensive and automated means to form a long string. These structures also have the strength to support the weight of the plants in the string. FIG. 3G shows a cross section of a typical string.
[366] In FIG. 3H, many strings 1 11a, 111b, are placed in parallel to form a layerl 03. The cross section FIG. 31 illustrates an embodiment of a permeability feature of the present invention, namely, the empty space between strings. This empty space enables the sharing of nutrients and light, that pass through between the strings and between the layers. This permeability also includes the ability of shoots and roots to overlap and share the same space.
[367] The advantages of the string interconnections is further highlighted in FIGS. 3J-3K wherein two layers 103a, 103b disposed vertically, each comprise a plurality of strings. One immediately notices the space saving in the cross section FIG. 2K where a portion of the plants of layer 103b occupy the space of the top layer 103a. The space between two layers is pz. It will be show later in a different embodiment that the period pz, interlayer space can be made to vary, plant manually or automatically, depending on the plant age and accordingly height.
[368] The plant age or the growing material product age is defined as the time that has elapsed from an embryonic time, an initial time, corresponding to an initial material mass size. This initial material may be seed, seedling, embryo, initial cell culture or initial microorganism microorganism culture. The initial age of material product, MP, is the initial time τ{ , having an initial mass, mi , which grows to a final age, final harvesting time, τ f , having an amplified final mass,
M , in a seed to harvest time r^ = τ f - i . The mass gain realized during this period is given by ), as derived in FIG. 8B.
Figure imgf000062_0001
[369] Now we provide in FIGS. 4A-4P more specific details of the construction of the SansSoil Growth Element, SGE. The term integral multifunction is defined as a structure that comprises at least two substructures integrally made, substantially permanently attached, so as to carry out at least two functions. These at least two functions are chosen from the group consisting of mechanical support, growth sustenance, germination, self-supplying of nutrients, self-supplying of light, a sensing environment, and communication of nutrients to nearest neighbor.
[370] The SGE in FIG. 4A comprises growth compartment or substructure la which mechanically and physiologically supports the growth of the root 2r and the shoot 2s to maturity. The substructure l a is integrally attached to a connecting conduit lb, that is in fluid communication with growth substructure l a, through an orifice or an opening l c. Fluid Id, flows through said orifice lc, supplying a stream If to the root. Conduit lb may have any cross section as shown in FIG. 4B.
[371] Conduit lb is removably attached to at least one source 3. Said attachment is preferably quick connect disconnect type with sealing function to prevent leakage, le. The source 3 provides essential resources and ingredients to optimally sustain plant growth. Said resources comprise at lease water and nutrients, but may also conduct and deliver light by means of total internal reflection mechanisms, well known in the fiber optic art and the back-light sources well know in the liquid crystal display art. The conduit may conduct electrical signals or power from sensors and to local LEDs integrated directly into the conduit lb.
[372] Conduit lb according to FIGS. 4C-4D serves to connect plural SGEs to form strings as described above, FIGS. 3F-3K, and to pass resources 3a from one SGE to another. Said resources include fluids, conducting signals from sensors 5, 5a, and energizing LEDs 4, to provide illumination 4b to local plants. [373] As shown in FIGS. 4E-4H, in certain embodiments the SGE also comprises a seed support structure lm, which functions to mechanically support the seed 2 (FIG. 4E), and to provide the optimal environment for high germination rate. By following the arrows in FIGS. 4E-4H, we show the emergence of the shoot 2a and root 2b (FIG. 4F), the growth of the seedling (FIGS. 4F and 4G), and finally the mature plant (FIG. 4H). This emphasizes the significance of the integral construction of the SGE, according to this embodiment, highlighting the capability of multi-functions which comprise: mechanical support of seed and mature plant, germination, local nutrient delivery, local delivery of light, environment sensing, and growing plant to maturity.
[374] The multi -function integral construction of SGE also highlights the local self-sufficiency of each SGE, that plays a significant role in maximizing three-dimensional space utilization efficiency. It also serves to make its distinction clear, relative to prior art plant growing practices, described above in connection with FIGS. 1A-1H.
[375] Since the plants follow the light direction, we can advantageously exploit this property to orient the plant growth in any desired direction as illustrated in FIG. 41, wherein the growth axis 6 forms an angle 6a with respect to the layer axis lj. In other embodiments, the whole string and plane, 10 can be oriented at an angle 6b with respect to the horizontal direction lv, as shown in FIG. 43.
[376] Yet in other embodiments, strings can be constructed and arranged so as to hang from top to bottom, 11, 12, with the SGEs oriented in the desired directions determined by the light as shown in FIGS. 4K-4M.
[377] In addition, there are system optimization benefits to interconnect SGE strings in the form of a network, 13, shown with respect to FIG. 4N, that combines series and parallel networks or combinations of strings attached to feeding structures, 14, 15, which receive resources 16, 17 from a master delivery system (not shown). The benefits of this arrangement include: increasing speed and flexibility of system assembly, reducing infrastructure cost, and optimizing consumable utilization efficiencies.
[378] Integrally made multi-function self-sufficient SGE may be attached to feed structure, or string interconnection sutures, 3, in a plurality of desired configurations, 20a-20e, shown in FIG. 4P, depending on the plant species and system design requirements. Persons skilled in the art may produce other configurations, without departing from the SGE network interconnectivity described and claimed in the present application.
[379] In conventional outdoor farming, the shoots, stems, and branches are constrained to grow upward in the direction of sun light, and the roots are constrained to grow downward in the soil where the water and nutrients reside, one embodiment of the present invention enables the SGE's to the plants upside down, as shown in FIG. 5A-5B. This is a benefit of the present invention that abandons the soil and can grow in artificial light that may emanate from any direction including from the bottom upward.
[380] Layers 200a and 200b comprise strings of SGEs 1, the bottom of each share the same space 201. Conveniently, the space 201 shared by the roots becomes the conduit to supply the nutrients 202 in the direction of the arrow. The string interconnections further provide for energy delivery to the LEDs to supply the illumination 203a, 203b.
[381] The integral SGE interconnected networked of 3D strings are supplied with (fed) required resources (nutrients and light) to sustain optimum growth by a plurality of methods including: direct connection of each string to sources, fogging, spraying and a combination thereof. FIGS. 6A-6E illustrate non liming examples of systems enclosures geometrical configuration, 100, 100b in relation to the feed subsystems, 112, 113, 114, 115, 116 delivering streams 117 fluid and light from all sides and optionally from the top and bottom.
[382] FIGS. 6C-6E shows stackable self sufficient configurations of complete system that comprise automated means to input (load) seeds and seedlings and harvesting the final product in a totally aspect manner sees or seedling trays. Said means may further comprise load-locks chambers as the interface between system 100 and the outside world, thereby ensuring aseptic loading and unloading.
[383] Multi-Layer Permeability
[384] To realize the full optional of 3D multi-layer farming, the preferred embodiments comprise means to maximize resource utilization efficiencies. This is accomplished by means of sharing these resources which include: illumination sources; nutrient delivery subsystems, supporting structures, and space. The means for sharing which are described in FIGS. 7A-7D result in the reduction of the system fixed costs, f, as well as the variable consumable costs, v, thereby ensuring maximum profitability, according to AgriPAL Eq. (1) above.
[385] The definition of permeability, according to the present invention, is the ability of a layer comprising at least one string of SGEs to pass resources from a first group of neighboring permeable layers, to a second group of neighboring permeable layers. The first and or the second group may comprise resource delivery sources. The total number of vertically disposed layers ranges from 2 to 10, and more preferably from 10 to 100 and even more preferably in excess of 100 layers.
[386] The permeability feature of the present invention enables the sharing of resources, including water, nutrient, illumination, heating and cooling and other sharable resources. The sharing of said resources enables their efficient, use thereby minimizing the ultimate product cost. The 3D yield or 3D productivity is measured in units of weight divided by volume and units of time. Therefore, the permeable means for sharing resources are designed to produce the maximum product weight in the most compact 3D space in the shortest time. These means are described in conjunction with FIGS. 7A-7D.
[387] Referring to FIG. 7A an exemplary multi-layer system 300 is shown and described. System 300 comprises at least layers 301 , 302 which are built by stringing a plurality of SGEs 1, as described in more details above and with respect to FIGS. 3F-3K. Layers 301, 302, and the connecting structures, 301 a- 301c, and , 302a-302c as well as SGE structures, are made substantially optically transparent so as to allow light rays 305a-305d from sources (not shown) to pass through layers 301, 302 to illuminate the plant shoots 303s, 304s of neighboring layers. The optical transparency of layer structure is made possible by use of transparent materials including but not limited to glass, polycarbonate, polyethylene, polypropylene and polystyrene.
[388] This means of achieving of light permeability enables multi-layers to share at least one light source growing plants, thereby realizing the maximum efficiency of the light source. As it may be appreciated, seedlings are small and are separated by wide lateral and vertical spaces. It takes months before the space between them is filled. During this time the light that is not absorbed by one layer, passes through to be absorbed by neighboring layers. The end result is that only a few light sources are used to illuminate a large number of layers. This immediately results in the reduction of initial capital cost of the light sources. For example, a 100 layer (permeable) system may be served by only one planar light source located on top of the system. By adding reflecting system walls, wasted light is minimized.
[389] By contrast, prior art 3D farming system in FIG. 1C contemplates using one set of light sources for each layer, clearly revealing inefficiencies of these systems. It further validates the significance of the permeable features in certain embodiments of the present invention.
[390] In addition to minimizing the initial fixed cost of light sources, the permeable layers also use the consumable light energy efficiently, lowering the variable cost of production. Any light that is not absorbed by a permeable layer passes through to adjacent layers to be consumed by plants in these layers. In conventional teachings, the light energy that is not absorbed by plants is irretrievably lost as a wasted resource.
[391] Referring to FIGS. 7B-7C, another type inventive permeability feature is described. It pertains to the roots 303r, 304r, and shoots 303s, 304s (stems, branches, leaves) of plants in one layer penetrating (sharing) the space of roots and shoots of plants in adjacent layers 306, 307. This space sharing achieves an unprecedented vertical compression, reducing the vertical height d, 308, 308a, many times. The absence of this space sharing would have required maximum height for roots which added to the maximum height of shoots, and the system would be vertically less compact. [392] FIG. 7D illustrates yet another type of permeability, which is the ability of one layer to pass through unabsorbed nutrients to adjacent layers. Nutrients essential for sustaining optimum growth of plants are provided by sources (not shown) in the space 309 occupied by at least the multi-layers 301, 302. Exemplary sources include fogging system, spraying system, and dripping systems which intermittently fill the space 309 with nutrients. These nutrients are delivered to the plants by means of foliar feeding or root feeding. FIGS. 3F-3K show that string of SGEs in each layer are spatially separated by empty spaces which allow the nutrients to pass from one layer to the next. This permeability also minimizes the number of feeding sources and their initial cost.
[393] 3D Multi-layer Continuous Flow Farming High Photosynthetic Efficiency
[394] The above described transformational new paradigm for agriculture which can be realized to solve the problems facing humanity and achieve food and plant based energy security is used in embodiments in which 3D multi-layer continuous flow farming with high photosynthetic efficiency is achieved. One key feature of the new paradigm is the understanding the profitability conditions of farming. This has been accomplished by the formulation of Agriculture Profitability Assurance Law, AgriPAL described herein. AgriPAL enables an enterprise to predict profitability of plant growing systems, to determine pricing of products, and to identify efficiency bottlenecks.
[395] Traveling Seed Amplifier and Continuous Flow Farming
[396] As described herein, AgriPAL and PGM are used as guiding principles enabling the realization of the full potential of 3D SansSoil farming paradigm. Emphasis has been placed on the ability to control physiological and physical parameters. In further embodiments, herein, higher gain are achieved therefore enabiling higher efficiency, increased space utilization efficiencies, by means of vertical compression, layer permeability and by making ultra-compact layers comprising strings of networks of integrally made SGEs.
[397]
[398] The teachings herein include three dimensional architectures that feature several examples of compactness and high space utilization efficiencies including: transparent layers 103 and SGE's 1 to recycle light to minimize wasted light, the overlap of root space and shoot space to minimize wasted space, and to provide more than one root and leaf feeding options.
[399] The systems described herein such as system 100 illustrated in FIG. 3 A and discussed above, including the various embodiments of the interconnections, SGEs, strings, arrays, networks and stacks, and other features described with respect to the figures herein, enable complete and self sufficient three-dimensional SanSSoil growing system for producing food, biofuel, and a plurality of plant made materials for industrial and medical applications. [400] We now introduce layer mobility, to endow the system described in FIG. 3A with enhanced capabilities including the temporal compression of the plant growth cycle, and an additional means to achieve more vertical space compression by means of automated, on the fly, adjustment of the mobile interlayer spacing according the age of the growing plant. This inventive feature of mobile layers enables the continuous flow farming by the synchronous planting and harvesting of material products, MP, including plant-made-products, PMP, for a wide spectrum of uses, including:
• all kinds of foods: staple cereals, legumes, vegetable, nutraceuticals
• bio-energy: peanuts (diesel), sugar beat (ethanol), Russian dandelion (butanol), Algae- biofuel
• Medicines: Lettuce, tobacco, algae (vaccines, therapeutic proteins, mAb).
• Indusrial Materials: natural rubber, polyethylene (PE), polypropylene (PP), enzymes, gels
• DNA, RNA, lipid, proteins, polysacharides
[401] Making the layers 103 mobile enables the realization of a traveling seed amplifier, TSA, system and method to continuous flow agriculture. TSA is analogous to a signal amplifier system in the electronics and communication fields, wherein a weak signal is connected to input port, immediately, synchronously, emerges from the output port as an amplified signal (replica of the input signal) with a large gain, (10-1000). The TSA system, 400, in FIG. 8A, is a 3D SansSoil continuous flow farming system for the production of material products.
[402] Analogous to a typical electronic signal amplifier, it amplifiers an initial material mass, m{ , applied, inserted, to an input port, at an initial time, τ; , then amplified to a final Mf , extracted, harvested, at an output port, harvesting port, at a time τ¾ . This final amplified mass having gain, Gsth= (Μ Λτ Λ - m^r,))/ 'ιη^τ^ = M( oo ) e ~k^ _ e ~k^ \ ; js a replica of the initial
»¾ (*,)
mass w^ . Even though, each initial mass requires a species dependent time, tsth = tf ~ τί to achieve the gain, Gsth , the rhythmic, periodic or near synchronous planting of mi and harvesting of its replica / , takes place at a harvesting period rh much shorter than rsth . Therefore, this inventive TSA system realizes an apparent growth cycle temporal compression of, rsth /rh = N , where N is the number of growth layers. Conventional farming, with N=l does not the benefit from temporal and special compression that result in temporal and spatial resource utilization efficiencies according to the instant invention. The TSA system may be designed to achieve gains, Gsth having values in the ranges of 2-10, preferably 10-1000, more preferably 1000- 100,000, for cell cultures, and event more preferably 100,000 to 100 million. To achieve a desired gain, the TSA system design may start with initial mass m^) , at any temporal position, rt , on the growth trajectory, including τ{ = 0 , or kt i = yktrsfh , where γ may be in the range of 0-0.1, or 0.1-0.2; or even 0.2-0.5
[403] The initial mass, mi , also referred to as seed mass, may be one or more masses selected from the group consistinf of seeds, seedlings, plant cell culture, micro-organism culture, microalgae culture, bacteria culture, fungi culture, stem cuttings, root cuttings, leaf cuttings, and eye cuttings. Said initial mass is planted in one or more SGEs, in one or more growth trays, wherein said SGEs are arranged one dimensional, two dimensional, and some cases 3 dimensional patterns, as in the cell culture trays 450 in FIG. 10A. These patterns may be regular periodic arrays, or other patterns advantageous for seed growth.
[404] In certain embodiments of the present invention, temporal compression factors N, ranging from 10 to 1000 preferably from 100 to 10,000 and even more preferably exceeding 10,000, are provided, for instance, in the case of algae and other culture made products, CMP. The high temporal compression factors have significant implications for growing food and energy. For example, if com cycle time rsth is 100 days, from seed to maturity, the 3D TSA system according to this invention, enables the planting and near synchronous harvesting of corn once per day or 10 times a day for compression range from 100 to 1000. In addition, since the layers N are disposed vertically, the third dimension, the volumetric productivity, and the 3D yield increase by N. This is saves arable land and enables food and biofuel to be planted and harvested daily, continuously or semi-continuously, without the concern that biofuel competing with food for 2D land and other resources.
[405] The TSA system for continuous growth of material products, MP, in FIG. 8A, comprises one or more towers, 401, 402, preferably in pairs. It may optionally comprise a single tower or a cluster of plurality of towers. It also comprises, housings 401a, 402a, an input, planning port, 404 an output harvesting port 405, a utility subsystem, 406, for resource delivery and system control (subsystem 102 in FIG. 3A), and a plurality of mobile layers 403a, 403b, traveling upward in tower 401 and downward in Tower 402. The construction of the MP growth layers in towers 401, 402 incorporate the inventive features described above. More specifically, the 3D array compactness, and space compression means, of interconnecting a plurality of SGEs into strings disposed in horizontal planes or vertical planes. The overall system performance also benefits from the multifunction capabilities, discussed above, of each individual SGE. The SGE may generally be used to amplify materials not only based on high plants, but also other materials including algae culture, and other cell cultures. The SGE for these other material sometimes are referred to as reactor growth elements or bio-reactor growth elements. [406] In normal operation, at least one layer 403c comprising at least one initial mass material, at a first age, τ{ , is admitted by transport means described below, FIG. 9A, into at least one initial location input location or planting port 404 in a position 404a. The initial mass material may be plant seed, seedling, or cell cultures which will be amplified. The layer 403c is moved one layer position upward and concurrently all other layers in both towers shift to the next adjacent position, until the last position 405a in the second tower is refilled. This last position 405a, had just been vacated a short period earlier, δτι by the harvesting operation of layer 403d at its second age τ f at the harvesting port 405. h The synchronicity period δτί is measured from: i)- the time of harvesting layer 403d; ii)- vacating the last position 405a; iii)- shifting all the layers to their adjacent positions; iv)-refilling position 405a; v)- vacating the first position 404a; and finally iv)- inserting layer 403c, in position 403a. The degree of synchronicity is defined thus: d ≡ δτί lrh . In normal operation, perfectly synchronous planting and harvesting is achieved in a design that achieves d « 0. In other near synchronous designs in normal operation, d may have values ranging from 0.001 to 0.1, or may approach 0.5. In these normal operations, the synchronicity is controlled by the system controller, or by manual operation. However, in other non-normal operations, d may exceed 0.5.
[407] The preferred embodiment for layer transport mechanism, further comprises a means for lateral transport of layer 403e, from position 404b in the first tower 401, to a second position 405b in the second tower 402. A non liming example to implement the lateral transport means, is an electromagnet that latches to layer 403 e, so that together they move laterally in a synchronized manner with the layer transport systems described in FIGS. 9A-9B. Once layer 403 e is in a predetermined position in tower 402, the electromagnet will unlatch, to enable layer 403 e in a condition move downward.
[408] The steps of admitting layer, 403c, shifting all layers, and harvesting layer 403d, are continuously, semi continuously, or intermittently, repeated with a regular compressed time period τ¾ , which determined by the following expression : h N ~ 2HS 2HS ' where, rsth = τ f - τ{ , the seed to harvest time, also the cycle time, is the difference between a first age, initial tine, τ{ and a second age, harvesting time, τ f . The cycle time ranges from 1-10 days in the case of algae, and other living cells, 20 to 40 days for lettuce, or from 80 to 120 for soybean, wheat and other annual plant, or 100 to 1000 days, in fruit trees. Hs , is the tower height 408, which ranges from 1 -10 m, or 10-100 m or even larger that 100 m; N , is the total number of layers 403, ranging from 10-100, or 100-1000;
hh , is the plant height at harvest time, before flowering for vegetable products, or after fruit, seed ripening.
h
CTSA≡ -^- , is the vertical space compression which reduces the average interlayer spacing, hav .
K
Compression factors between 2 and 5 are possible even 5 to 10 in systems where plant strings are mobile in two spatial coordinates and the plant spacings in two directions are automatically adjustable according to plant age. The interlayer/^ , 408a, varies from the smallest height of the seed/seedling layer at position 404a, to the maximum height, hh , at position 405a. This results in the compressed average height hav .
[409] The ability to adjust the interlayer spacing 408a, in real time, while the layers are transported, to maintain the correct interlayer spacing according to the plant age, is accomplished by the unique transport mechanism depicted in FIGS. 6A-6B described below. This uniqueness enables tens of layers to move, adjust and maintain the correct interlayer pacing, yet they are able to receive nutrients by inventive delivery subsystems according to the present invention, in a many impossible to achieve using prior art teachings of hydroponic and aeroponic methods.
[410] The compression factor also incorporates the other space saving features discussed above, including: the permeability, the shoot and rood volume overlap, the ultra-compactness of SGE connected in networked of strings in layers 103, 403.
[411] Returning to FIG. 8A, the two tower housings 401a, 402a, instead of being separated with a space 407, they may have a single common housing. They optionally may be sheltered in yet a third housing which also shelters additional tower cluster, downstream processing equipment, and other facilities. In other options, when the TSA towers are housed in a larger enclosed protective environment, the housing structures 401 a, 402a, may be open to said larger protective environment, or may be eliminated altogether. Additionally, the tower housings may be substantially transparent, to optionally allow solar illumination, in addition to artificial lighting. They may also comprise variable transmission windows, retractable curtains comprising filters, absorbers, and reflectors.
[412] The subsystem 406 controls all aspects of plant growth delivered by subsystem 102, as discussed above and illustrated in FIG. 3 A, in addition it controls additional functions of TSA system 400, including: vertical layer transport, lateral transport (no shown), tower rotation, planting and harvesting, and load lock control. In another aspect of the invention, the TSA tower system 400 may be a member of tower clusters, each comprising a plurality of towers. It is contemplated that the subsystem 406 of each TSA tower communicates with a cluster master controller remotely, the latter, in turn, may communicate with yet another master controller located in a remote location. Persons familiar with the art of remote control can execute these tasks.
[413] In another aspect of the invention, it is the towers can be rotated at an appropriate speed to track the sun and or to improve the illumination uniformity from the sun or an artificial lighting source;
[414] In other embodiments, to ensure food safety, the towers are equipped with sterility functions, to protect the plants from harmful pathogens and also to consumers from harmful pathogens. It is contemplated that isolation may be achieved by installing load locks in the planting and harvesting ports 404, 405. Each load lock is a chamber comprising sealable doors that enable the sequential transfer of seed layers in (initial mass) in, and harvested products out. The seed layers are admitted through a first door that is in communication with the outside environment. This door is subsequently sealed, and the layers are sterilized in situ. Subsequently, a second door, which is in communication with the main TSA system housing, is opened, and the layer 403 c is transferred to its position 404a. The next step is resealing the second door, making it ready for the next repeat cycle. The operation of harvesting load lock chamber is the same except the steps are in reverse. Aspects of the invention contemplate automated transfer of layers and trays from chambers 404, 405, or optionally semiautomatic or manual transfer. In other embodiments, human operators may be involved in the process of planting and harvesting inside the sterilization load lock chambers. In this case, sterilization methods for humans will be adopted as is well known in the sterilization art.
[415] The above operation is referred to as continuous flow farming. As in the case of electronic signal amplifier analogy, the inventive TSA, daily, continuously, admits, plants seeds/seedlings and harvests synchronously products for immediate consumption by consumers or for downstream processing converting them into other forms of the products. By the term continuous we mean a synchronous planting and harvesting operation at a periodic rate, N I Tsth = l l rh . This is contrasted with conventional agriculture, wherein cereal seeds are planted in the fall and harvested late summer or after rsth of about 8 to 9 months have elapsed. In the present invention planting and synchronously harvesting [ intermittently] once every day or every 5 hours is referred to as continuous or semi-continuous because of the regularity [regular period] of the operations. Furthermore, in continuous flow farming, the daily harvesting, in some cases several times a day, for very tall towers, takes place uninterruptedly, 24 hours a day all year around. Even though, there is a non zero time period between the synchronous planting and harvesting, the operation is 24/7 uninterrupted operation and on a time average basis, we use the term continuous relative to conventional farming wherein the period between planting and harvesting may be a year or longer.
[416] This unprecedented productivity is made possible by the 3D SansSoil controlled environment architecture, and TSA. Depending on the number of layers, the plant species, and the height of the towers, enormous arable land savings is realizable by having 3D hectares in the sky. For examples, sugar beet 2D yield is about 16ton/hectare/year of sugar, assuming harvest index of 16% (sugar output). Using 100 meter TSA tower, continuous flow farming can produce 173 tons/hectare, of sugar each day continuously or 63,145, t/ha/year. This is because the plant height is only 50 cm, making it naturally suitable for 3D architecture. This example illustrates an astonishing land saving of about 4000 fold. Consequently, this TSA continuous flow farming has the potential to solve the arable land limitation problem, that has posed a dilemma of feeding the world and the resource competition associated with the issue of "food vs. biofuel.
[417] TSA Vertical Compression Embodiment
[418] Described herein are temporal, spatial and physiological loss mechanisms, contributing to the low plant efficiencies, -0.001 %, Table 1 , inventive means and methods are disclosed to recover between 10-100 times of those losses. The present TSA embodiment contributes two compression mechanisms:
1. Temporal compression of plant cycle time which is shown examining the planting and synchronous harvesting time expression given by:
T h T (C h )
T¾ _ _j^_ K _^th_ _— 7^£_ji— sth_ ^ reveals that the intrinsic physiological plant cycle time is
N 2H, 2H,
(CTSAhh)
effectively compressed by a factor, N =— . We refer to this as the agronomic temporal compression, "pseudo-compression", which is designed in the TSA tower system. The inventive variable pitch screw layer (tray) transport mechanism described in FIGS. 9A-9B, is the key contributor to the temporal compression paradigm.
Typical annual crops, soy bean, and cereals have intrinsic rsth in the range of 100-120 days, and
(0.33 x \m)\20 days Λ„ , nh~\ m, will achieve a planting/harvesting TSA time, r¾ = = 0.2 days , lor
2 x l00«¾
100 m tower and CTSA -0.333. This is a non limiting example to illustrate the power of TSA 3D sansSoil farming architecture. The antisense times varying according to species and growth conditions. Another example related to algae culture for biofuel production, rsth ~\0 days, and hh~0.0\ m, will achieve a planting/harvesting time
(I x 0.0lm)l0 days n ,
Th = - — = 0.0005 day or 22sec.
2 x 100m
2. Vertical space compression factor, CTSA = hav lhh , is another vertical space saving method achieved by means of the variable pitch screw mechanism. Recognizing that the plant height in the first of 10-20 days is much smaller than the full height hh at maturity, affords the opportunity to reduce the overall tower height for the desired optimum number of layers, by a factor Qx4 = Kv I K■> where hav is an average interlayer spacing determined by the physiology of the plant, its temporal growth trajectory, and engineering design considerations which are presented in the next section.
[419] FIG. 8B is an exemplary plant height growth trajectory curve and plant biomass growth trajectory described, respectively, by the following expressions: h(t)∞h(∞)(\ - e ~k'');MBM (t)∞M(∞)(\ - e ~k,t) . These functions illustrative and are not intended to limit the present invention. These functions also approximately describe the growth trajectory of other living cell cultures, microorganism, and the like. These functions may composites which comprise two or more growth phases of different growth rates. For example, a composite function may have an exponentially rising component, fx it) = mp^ with a first growth rate, kx , and a second components f2(t) = (∞)(1 - e~k%t) , wherein at a certain growth phase at a certain time, these components and their first derivatives must match.
[420] There are at least two possible product scenarios:
i)- Harvesting the product in the vegetative state, point A, where the harvesting height hh is smaller than the maximum height h(∞) at a harvesting time rsth(A) .
ii)-Harvesting the product after full maturity and ripening the fruit and the seed, at point B, where the harvesting height hh is the maximum height h(∞) at a harvesting time, rsth (B) .
These growth trajectories are experimentally determined for each plant and its growth environment.
[421] We use soybean growth trajectory to show the role of the physiology plays in TSA temporal and spatial compressions with the air of FIGS. 8C-8D. In a TSA system, the selected mobile layers at plant heights h0,h5 ,h20,h40, h, andhU0, (other layers are not shown for simplicity) correspond different times on the growth trajectory of soy bean. These layers also show the soy bean morphologies at different ages, from seedling emergence, at h0 to the last layer hl20 , after 120 days, which is ready for harvest. In order to illustrate vertical space compression leading to an average height hav and a compression factor CTSA = hav I hh , the cycle time for soybean, is divided into 120 time intervals, At =1 day. In this non-limiting illustrative example, soybean seeds would be planted daily at, and mature dry soybean pods are harvested synchronously (daily) at hl20. One seed layer goes up one position in the left TSA tower and mature harvested layer goes down in the right TSA tower. This is a daily amplification of the seed biomass. In other examples when N is 1000 layers and beyond, then At will be less than 0.1 day. In the case of species with intrinsic rsth of hours or days, At will be measured in minutes or even seconds.
[422] In FIG. 8D, a segment 410a of the whole soybean growth trajectory 410 is shown on the left. The segment 410a is magnified to show more details of the time period corresponding to heights from z0 to h20 , wherein said time period is divided into 20 intervals At . Also shown are layers 403 vertically located in their respective heights from z0 to h20. By examining the height of each layer and its one-to-one correspondence to the height on the growth trajectories, 410, 410a, it is revealed that the layers are traveling at a constant speed along the plant growth trajectories 410, 410a. This means that the interlayer distance is automatically adjusted to keep up with the growth of plant height. It is also revealed that the interlayer distances, early in the growth stage, of layers h0 to hw are much smaller than the interlayer distances of the later stage, layers hw to h20 . This proves that the interlayer distance averaged over the whole 120 layers is compressed by a factor CTSA = hav lhh < 1. It can be shown, that depending of the species growth trajectory and whether the harvest time of the product is rsth(A) , or rsth (B) compression factors between 1.5 and 4 are achievable. Using suspended SGE strings that allow variable inter-SGE spacing, px and py, in addition to the vertical, pz, just described, compression factors approaching 10 are possible.
[423] The determination of the compression factor is subjected to engineering design considerations related to the structure and cost of the plant growth layers. FIG. 8E is an illustration of linearization of the growth trajectory that aid in determining the number of layers and interlayer spacing for each of the 5 linearized segments 410a to 410e.
[424] As shown in FIG. 8F, in other aspects of the present invention, flexibility is allowed with regard to the locations of the planting and harvesting ports, 404a, 405 a in TSA system 400d, or 404b, 405b, 405c in system 400e. The system may have more than one planting port or more than one harvesting port in locations determined by overall function of the system.
[425] In yet another aspect of the invention, the system, 400f, has growth layers 403 which may be disposed in the y-z spatial coordinates, i.e., vertical planes as shown in FIG. 8G. In this case the TSA transport system moves the layers horizontally with a constant velocity so as to adjust in real time the interlayer spacing 420a at the seedling stage to spacing 420b near maturity. This produces a TSA compression in the y direction. In this case the hanging layers may also comprise a plurality of individual independently hanging strings, of SGEs, as shown in FIGS. 4L, 4N and 4P. The spacings between these SGEs vary in the x direction from seedling to maturing spacing, thereby allowing yet a third TSA compression factor. The overall TSA compression factors in at least two spatial coordinate directions can approach 10.
[426] TSA Transport Mechanism
[427] The above temporal plant cycle and spatial compression factors are made possible by means of the TSA transport system, a key aspect of the present invention which is described with the aid of FIGS. 9A-9B. In the broadest sense, it is a system 411, that transports a plurality of layers, 403, at a specific velocity, in at least one direction, and, automatically adjusts and maintains different interlayer spacings, determined by an algorithm that is executed by the system controller.
[428] This algorithm is determined by factors that include the physiological trajectory, growth environment, engineering and cost considerations. In a specific preferred embodiment, the TSA transport system comprises one or more screw rods (or auger-like helical rods) 412a, 412b, having a helical thread comprising one or more pitches, p1 , p2, p3, p4, p5, p6, For TSA towers enabled to have large temporal and spatial compression factors, the screw rods are designed to have variable pitches, a plurality of pitches, the number of which is selected from the ranges 1-10; 10-20, 20-100. These will result in temporal compression factors: between 1 and 10, preferably 10 to 100, and even more preferably, 100-1000, and spatial compression factors, ranging from 1 to 10. Compression factors of larger than 10 as also achievable, according to the present invention, by means of the cumulative effects of space saving from root-shoot overlap, from the compactness of the integral construction of SGEs, as discussed above, and the TSA automated variable interlayer spacing adjuster 411 in FIGS. 9A-9B.
[429] The growth layers 403 generally comprise one or more trays (plurality of trays) 403t each comprises one or more SGEs, and a frame or a handle structure 403h that supports the trays. One or more trays are removably attached to their respective handle structures. Even more preferably, in some embodiments, the trays are deposable, one time use. Said one or more SGEs, are in the form of at least one network of strings, and more preferably in the form of one dimensional or two dimensional arrays. Each tray is in communication with fluid delivery and light delivery subsystems (not shown). The handle structure 403h is in direct physical communication with the screw rods 412a, 412b at contact regions 416c, and 417c. When the rods experience synchronous rotation in the directions 416, 417, the contact regions 416c, 417c of the handle structure are pushed upward or downward, moving with them all layers 403. The interlayer spacings are maintained by the rod pitch associated with each tray vertical location and maintain spacings. The tray and handle thicknesses may not have the same values. These thicknesses are chosen from these ranges: 10-100 micron, 100-1000 microns, 1 -10 mm, and 10-100 mm. While the periodic or non periodic spacings between SGEs are chosen from these ranges: 10-100 micron; 100-1000 microns, 1 -10 mm, 10-100 mm, and 100-1000 mm.
[430] The thread-form of the screw rods are machined in such a way that the depth and the flank shapes of the thread can accommodate and hold the handle structures 403h of the growth layers and have the strength to accommodate the layer's load. The spacing between the screw rods enables the growth layers to be held firmly yet with the ability to be easily removable, during the steps of planting and harvesting. For synchronous rotation, the screw rods 412a and 412b are coupled to a subsystem comprising at least one motor, at least of one set of chain belt- gear arrangement and supporting structures fixed to the mainframe housing. The rods counter- rotate, 416, 417, cooperating synchronously to lift all the layers 403 upward or downward at the contact regions 416c, 417c. While the angular velocity is kept contestant, the layers move at different linear speeds depending on the local pitch. This results in interlayer spacings 413, 414, 415 having different values at different heights determined by the pitch values. The pitch variation as a function of height is determined by an algorithm which at least reflects the plant growth trajectory that is measured experimentally.
[431] The number of screw rods needed to transport the growth layers varies from 1 to 10. For example in system 400f, the hanging growth layers 403 are transported to the right by means of a single screw rod 412c, that is it rotates, it translates the layers linearly, while at the same time adjusts and maintains the correct interlayer spacings 420a, 420b, according to the age of the plants. This single screw rod arrangement, in addition to its simplicity, and low cost, it has a major additional advantage in that it does not need to support the weight of the hanging layers. It only needs to push to translate the layers after overcoming frictional forces.
[432] In other embodiments, when the plant growing layers are horizontally disposed and move up and down (z direction), at least three screw rods are required to balance weight support against gravity forces. In other instances, 4, 6 or even 8 rods may be required.
[433] In another aspect of the invention, the variable pitch thread-form may be incorporated in the inner surface of a rotating cylindrical housing to enable the upward or downward motion of N layers. Said N growth layers have areas or diameters designed to efficiently occupy the volume of the rotating cylindrical housing. The incorporation of the thread-form may be accomplished by means of machining (or embossing) substantially the entire inner surface. To lower the cost, especially when the diameter exceeds 1 meter, it may also be accomplished by the partial machining (or embossing) of the inner surface. The partial machined (embossed) area covered, may be in the form of a plurality of axially oriented thread-form strips. The number of these strips may be in the range of 2 to 6 or 6-24 if the diameter is very large. The length of the strip is approximately the length of the cylinder, and its width is a fraction οΐ π χ diameter . This fraction may be between 1/8 and 1/32, or may be smaller than 1/32, depending on the number of strips and the design of the layer structure.
[434] Yet another option is to avoid machining or embossing the inner surface, and instead, a plurality of thread-from strips is fastened to the inner surface of the cylindrical housing.
[435] Although the variable pitch screw rod system is the most advantageous solution to the problem, of self-adjusting interlayer spacing as a function of growth, there are other mechanisms persons skilled in the art may conceive based on moving belts and chains. Applicant has discovered that the variable pitch rod mechanism features many more advantages including: high performance, compactness, low noise, low cost, flexibility, and scalability to very high tower heights.
[436] TSA Embodiments
[437] TSA embodiments according to the present invention have been designed, built and evaluated for growing lettuce as a vehicle to validate its operability, and the key inventive functions that make the TSA unique. FIGS. 9C-9E TSE system. A system 400a has a base of 1 m2 and a height of 1 meter, designed to accommodate 20 growth layers. Lettuce was chosen as an example that represents food products, and when genetically transformed, it represents medicinal products, vaccines, and antibiotics.
[438] In FIG. 9C, the main frame extruded aluminum housing structure, 418, is shown, to which four screw rods, 412c, 412d, 412e, are attached. Also shown are sprocket gears, a chain belt and a manually rotated wheel. The motor driving this transport mechanism is on top in FIG.9D. Aluminum frames or handles 403h are shown supporting transparent growing trays 4031. The frame, 403h along with 4 trays 403t constitute a complete layer 403.
[439] FIG. 9E shows two perspectives views of a substantially complete TSA system, 400c, comprising: the housing 418, the planting port 404, the harvesting port 405, plurality of growth layers 403 populated with lettuce at ages corresponding their height, permeable to light, nutrient, and roots and shoots of neighboring layers. As can be seen, the interlayer spacing varies from very small at the bottom, 2.5 cm, to 25 cm at the harvesting port, reflecting the ages of lettuce. The system also comprises a master controller for controlling the motion of the layers, the pulsed LED lighting, water, nutrient delivery, pH, temperature, and relative humidity, as described herein. [440] FIG. 9F, illustrates system 400d which is a scaled-up embodiment of system 400c, in FIG. 9E, with 4 screw rods 412f for upward motion and 4 screw rods 412g for downward motion. This is a modular design which can be built into a pair of towers of different scales with heights ranging from few meters to more than 100 meters, each has a chamber 401a for layers 403 that move upward, and chamber 402a for layers that move downward. The side walls are shown to comprise the LED illumination option. The housing may be transparent so that solar illumination is provided as an option.
[441] The transparent trays 403 are uniquely designed in a hexagonal SGE array configuration capable of many functions, including, germination, amplification, mobility, interlayer spacing adjustment, and water and nutrient delivery with virtually no plumbing. The transparent hexagonal arrays are visible in the trays of FIGS. 9C-9D. The hexagonal array of a specific layer is rotated relative to its neighboring layers, in the manner to allow said specific layer to receive water and nutrient of a layer on top, delivers water and nutrients to its own plants, and relay the rest to the bottom neighboring layers. This relaying function enables the entire layer to receive an appropriate nutrient level needed to sustain growth.
[442] Levitated Bio-Reactor for Culture Made Products
[443] In another preferred embodiment, the TSA systems along with the TSA transport mechanisms described above, FIGS. 9A-9B and systems shown in FIGS. 9C-9F for growing lettuce, may also be used for cell culture (suspended of immobilized) for the production of MP, including plant made products, PMP, and culture-made-products, CMP. They may also be used for the production of other materials that rely on catalytic or enzymatic conversion reactions of one or more substrates. The latter reaction processes are analogues to cell culture methods, except that the catalysts are made of non-living matter, including molecular sieve, zeolite families, metals, and other particles comprising acid or basic catalytic sites. All of these methods for the production of matter benefit from the inventive features of TSA and TSA transport mechanism.
[444] The culture methods may include prokaryote, eukaryote cells, microorganisms, algae, cyano-bacteria, other bacteria and fungi, and a variety living organisms generally referred to as autotroph, photoautotroph, heterotroph, or mixotroph. These cells represent naturally evolved species or genetically transformed by well known recombinant DNA engineering methods. These methods may include transient (plastids) or nuclear genetic transformation. In these cases, the trays are specifically designed to comprise one dimensional or two dimensional SGE arrays 400 in the form of micro-wells or troughs, 451 a, 451b, 451 c, 45 Id, 45 le and 45 If, as shown in FIGS. 10A-10B. Each composite TSA mobile layer 403x, comprising a handle structure, 403h, and one or more trays 451. In a TSA system, a plurality of TSA composite mobile layers 403x, are transported according to the present invention by means of the TSA transport mechanism 411, FIGS. 9A-9B.
[445] Each of the plurality of trays 451, in the composite layer, is designed to have a specific structural strength that enables the stacking of a large number of trays, so that they can move as one unit, a composite layer, and to support the total load including that of the culture mass 452. The trays 541 are designed to comprise self-alignment features relative to the neighboring layers and to maintain inter-tray spacing sc .
[446] The trays 451 are so designed as to facilitate the filling, or emptying of the culture and culture media, in a single operation, of all the micro-wells 451a in a composite layer 403x. The single filling operating enables the automatic adjustment of the micro-well levels 454 to achieve an identical full height dc . This single operation filling is accomplished by means of perforations 453 in all the trays. The culture growth element arrays of the trays have periods in two dimensions pa , nd pa , which may be in the ranges of 10 to 100 microns, 100 to 1000 microns, 1000 to 100,000.
[447] In certain embodiments of a TSA-based bioreactor, ultra-high surface to volume ratio of the micro-wells is achieved, to enable fastest gas exchange as illustrated by the arrows 456 in FIG. 10B which represent the diffusion of metabolite gases in and out, including 02, C02, alcohols, and other volatile primary or secondary metabolites, depending aerobic, anaerobic or fermentation metabolism of the growing cells. It is desirable to maximize the gas exchange speed for metabolism and growth conditions. This is a accomplished by means of decreasing diffusion lengths of metabolites and increasing the diffusion speeds, such outcomes are
1
facilitated by maximizing the surface to volume ratio which is related to— . This is maximized by keeping the depths of the micro-wells as shallow as possible, which is satisfied by keeping dc < pa, pa or even more preferably dc « pa , pa . Exemplary non-limiting dc values are chosen from the ranges: 10 micron to 100 microns or 100 micron to 5000 microns. The values are optimized based on well known behavior of dissolutions of metabolites in culture media, temperatures, and pressures.
[448] Making TSA bioreactor exemplified by the composite layer 403x constructions as in FIG. 10A-10B makes a large volume system production with maximum efficiency, productivity, yield flexibility and scalability at the lowest cost. One of the key to maximizing productivity (volume to volume) is maximizing the culture density. The present invention ensures that, by achieving a large surface to volume ratio with ultra-shallow depth dc , and the immediate access of each cell to the ambient environment for nutrients, and for optimum gas exchanges. Productivities well in excess of 100 niL/L and even more than 500 mL/L are possible. In another aspect of the invention, the culture cells may be immobilized in trays and in mobile layers which can be intergraded in TSA systems that benefit form the high density and productivity features.
[449] Conventional bioreactor systems face scalability problems and their price/performance degrades as higher production is contemplated. The present invention enables a system to be scaled up from few liters to 100,000 liters, retaining the price performance predicted from the operation of a single micro-well or a single tray. The gas exchange remains optimized regardless of the systems size. Typical inter-tray spacings sc may be chosen from the ranges sc = dc to sc = 2dc , this will facilitate gas exchanges, as well as the filling and emptying of the culture media.
[450] The culture array elements, 451a, 451b, 451c, 45 Id, 45 le and 45 If, may be designed to have diverse periodic array geometrical arrangements, configurations and micro-well trough shapes (physical profiles), depending on the benefits that accrues for a specific application growth conditions and growth environment.
[451] One preferred thin walled trough is the concave shape 451 c designed from a material and a surface coating 455a that prevents the cell culture and cell culture medium 452a from sticking. This phenomenon is referred to as fouling in prior art bioreactors, especially, algae bioreactors. In these reactors, fouling is considered to be one of major hurdle preventing large scale algae from reaching profitability, as tested by our AgriPAL condition. This non-stick feature according to the present invention enables the filling and emptying of the wells with minimum friction, so that the fluid flows or glides effortlessly and enables the reuse of trays very large number growth cycles ranging from 100 to 1000 or from 1000 to 10,000 and more preferably approaching 100,000 cycles.
[452] Hydrophobic coatings and even more preferably super-hydrophobic coatings, SHC, are contemplated. These coatings are well known in the art. The SHC is characterized by a fluid 452a having very large contact angle in the range of 150° and 180°. This enables the culture medium to form a spherical bead (or cylindrical bead in one dimensional trough) with near zero contact area with the micro-well surface 455 a. Such near zero contact area beads, made of culture medium, are inoculated with of growing cell culture.
[453] Since the bead volume is more than a million times larger than a single cell volume, the beads behave as though they are levitated bio-reactors, hereafter; they are referred to by the acronym, LBR. They are levitated, because nearly the entire outer surface of the bead is surrounded by ambient environment exchanging with it metabolite gases with minimum impedance, as the arrow directions 456 show. To further facilitate the gas exchanges 456, with the ambient environment, the LBR 452b in trough 45 Id, is made to nearly float on the surface 455b that is perforated, mesh-like, porous or otherwise permeable to metabolites. For very small LBR beads having diameters in the range of 100 micron to 1000 micron, large surface to volume ratios are achieved, thereby ensuring optimum gas exchange and highest productivity that exceed 100 mL/L or even exceed 500 mL/L.
[454] LBR comprising diverse shapes and cross sectional areas 452c, 452d, FIG. 7B, may be produced with the supporting micro-well shapes 45 l e, 45 If, comprising shallow depths, and surfaces that are permeable to metabolites. They are designed to maximize gas exchanges to maintain high cell viability and density. The illustrated shapes and cross-sections are meant to non-liming examples. Persons skilled in the art will be able to select other geometries that have advantageous features.
[455] . FIG. IOC illustrates an embodiment of layers 460, and 461, comprising a handle structure 460h, 461h, and a plurality of LBR's, 452e and 452f which have their surfaces in contact with the ambient environments for effective exchange of metabolites 456. FIG. 10D illustrates an embodiment of a layer 462 comprising a handle structure 462h, at one culture chamber 452g, and a plurality of gas chambers 463 which are in communication with the culture through permeable surfaces or perforated surfaces covered with super-hydrophobic coatings 465. The latter ensures non-stick surfaces to enable the filling and emptying of the chamber repeated with minimum fouling. The arrows 464 indicate the direction of exchange of metabolites which are designed to have short diffusion lengths and diffusion times, and maximum surface to volume ratio for high density and productivity.
[456] The geometrical configurations, physical profiles and appearances of components, illustrated in FIGS. 9A-9F, FIGS. 10A-10D, are non limiting examples. Skilled practitioners will be able to conceiver variations which will not depart from the inventive features taught by the 3D SansSoil farming paradigm, the TSA tower implementations, the TSA transport mechanisms, and the non-stick culture in the multi-layered arrangements of micro-well levitated bioreactors.
[457] FIG.11 is an illustration of a TSA tower 400 that describes other aspects of the invention related to energy requirements to sustain plant growth. Specifically, it emphasizes the systems' flexibility in using diverse energy sources and forms, individually or in combination. Unlike conventional 2D agriculture which is constrained to use the only sun illumination, in the TSA system 400, direct sun energy is not a requirement, it is an option. When solar illumination is used with TSA, the system housing is designed to be transparent to the wavelength relevant to photosynthesis.
[458] In the case of artificial illumination, the system generally comprises strings of LED 421, localized near the growing plants in an optimized configuration so as to achieve uniform illumination. These LEDs are driven by means of an electronic subsystem that delivers to the plants light pulses comprising variable frequency, variable pulse widths, shapes, and duty cycles.
Applicant has used pulsed illumination to optimize the enzymatic kinetics that experimentally demonstrated improvements in the energy utilization efficiency ranging from 4 to 10, dependent on the plant species. As discussed herein, artificial illumination, and indoor controlled environment farming, benefit from the ability to increase the photo synthetic efficiency by factors ranging from 10 to 100, AgriPAL, Eq. (1), above, and EVJ"≡ rfE≡ gj]E .
[459] The LED's primary energy is derived from several electric power options shown in FIG.
11, including:
Photovoltaic arrays, PV which harvest and convert solar radiation to electric power, with efficiencies ranging from 10% to 20% or even higher. This electric power is delivered to the pulse generating subsystem that drives the LED 421. This option combines all the advantages of the 3D SansSoil TSA farming with the limitless availability of low cost renewable energy from the sun. The cost advantage is realizable especially when the PV arrays are placed on land that is not suitable for agriculture.
Wind turbine electric power generation is another source delivered to power the pulsed
LED strings 421. This option enables TSA tower farming for food production in remote areas on lands that are not suitable for conventional agriculture. Most advantageously in geographic locations where the temperature swings are very high and unpredictable. Whether these locations are in near arctic climates or very hot deserts, the TSA controlled environment will be suitable for efficient food and biofuel production.
Electricity from other renewable sources combined with LEDs is suitable for power system 400 including hydro power, geothermal, ocean waves and tidal.
Grid provided electricity in combination with LEDs is also suitable to power system 400.
Grid derives its electricity from coal, natural gas, other fossil fuels, and nuclear fuels.
Dedicated multi-fuel generators consuming fossil fuels and bio mass are particularly suitable for TSA system because they combine the following advantages
a. The ability to sequester C02 by feeding to the plants for conversion into food of or bio- energy products. This lowers the cost energy, helps the environment and increase profitability.
b. Overall energy cost reduction by eliminating many costs associated grid based electricity, including location flexibility not tied to transmission line availability,
c. Recycling of TSA self-generated biomass into electricity using the same multi-fuel
generator to drive TSA for illumination, heating, cooling and general TSA function controls. [460] The self-sufficiency and modularity of the contemplated system will enable easy scale up to larger production volumes, once a module is optimized in terms of yield, productivity per unit volume, resource utilization efficiency and low production cost. A scaled up production system comprising plurality of modules that may be stacked vertically to any desired height, the "sky is the limit", the ultimate potential of 3D agriculture, realizing the goal of food and energy security with no resource competition.
[461] The present invention comprises aspects of AgriPAL that deal with maximizing space utilization efficiencies, which include three dimensional, 3D, soil-less, SansSoil, plant growing structures and subsystems to sustain growth. More specifically, the aspects that reduce the cost of said structures and subsystems which lead to the minimization of the parameter f in Eq. (1). Even more specifically, the increase of ge E which is a function of the n, the number of vertical layers in 3D farming systems wherein the productivity and yield are measured in units of ton/hectare-meter-year, or ton/m3-time, or kg/m3-day. The fundamental structures associated with these aspects are described herein with respect to FIG. 3 A.
[462] The SanSSoil method for indoor growing plants and other photosynthetic organisms comprises the following steps:
1. Providing substantially impermeable environment 101.
2. Providing at least one growth layer, 103 capable of sustaining growth of plant a plant specie, and comprises at least on integrally made SGE 1, for example as in FIG. 2B.
3. Providing seeds to be germinated in at least one SGE to establish a seedling that is viable for further growth, or alternatively, providing at least one seedling that is fixed in an SGE to adapt and become viable for further growth.
4. Providing light having optimized wavelength, intensity, and temporal characteristics.
5. Selecting a program stored in the control system that comprises optimized temporal steps, and parameter values for the plant specie, which is designed to give an optimum growth trajectory for the desired product.
6. Activating the control system to start the growth protocol for the desired specie.
7. Monitoring the growth conditions by means of sensors to enable the control system make adjustments, as needed, follow the designed growth trajectory.
8. Harvesting the products
9. Repeating the cycles for either batch mode culture or continuous culture.
[463] The SanSSoil method further comprises the steps:
n
a. Varying the parameters in EVI' = g^E = (GspGtGf )(Q gtΕ , b. Establishing the optimum range, minimum and maximum values for each for each parameters
c. Recording and storing said optimum ranges for each species.
d. Providing a program which incorporates said optimum ranges and established the growth trajectory for each species that leads to harvesting the desired product e. Loading said program into system controller 102
f. Commanding programmed system controlled 102 to execute steps 3 through 9.
[464] This is an exemplary method that harnesses the principles and the premises of the invention described herein. More specifically, the use of AgriPAL, in conjunction with the
n
detailed physiological parameter transparency given by EVV = gJ]E = (Gs?)G(G/)(]_[g!.)¾ to profitably produce food and plant derived fuels and other materials. Therefore, the steps described should not be limiting, for skilled practitioner may conceive improvements that do not depart for the inventive methods, means, principles and features.
[465] As described herein, various embodiments are implemented by a computer system or controller. An exemplary block diagram of a computer system 500 by which the systems and methods of the present invention can be implemented is shown in FIG. 12. Computer system 500 includes a processor 502, such as a central processing unit, an input/output interface 510 and support circuitry 512. In certain embodiments, where the computer 500 requires a direct human interface, a display 516 and an input device 516 such as a keyboard, mouse, pointer or touch- screen enabled input are also provided. The display 516, input device 518, processor 502, and support circuitry 512 are shown connected to a bus 514 which also connects to a memory 520. Memory 520 includes program storage memory 530 and data storage memory 540. Note that while computer 500 is depicted with direct human interface components display 516 and input device 518, programming of modules and exportation of data can alternatively be accomplished over the interface 510, for instance, where the computer 500 is connected to a network and the programming and display operations occur on another associated computer, or via a detachable input device as is known with respect to interfacing programmable logic controllers.
[466] Program storage memory 530 and data storage memory 540 can each comprise volatile (RAM) and non-volatile (ROM) memory units and can also comprise hard disk and backup storage capacity, and both program storage memory 530 and data storage memory 540 can be embodied in a single memory device or separated in plural memory devices. Program storage memory 530 stores software program modules and associated data for operating said software program modules, for instance, for carrying out the AgriPAL conditions, enhanced EVI derived from the new Plant Growth Model, PGM, described herein. Data storage memory 540 stores information concerning the correct amount of nutrients, the correct pH and the optimum environmental conditions for maximum yield. One of skill in the art will appreciate from the description herein that the contents of the program storage memory and the data storage memory are apparent, e.g., based on the description associated with FIG. 3A.
[467] It is to be appreciated that the computer system 500 can be any computer such as a personal computer, minicomputer, workstation, mainframe, a dedicated controller such as a programmable logic controller, or a combination thereof. While the computer system 500 is shown, for illustration purposes, as a single computer unit, the system can comprise a group/farm of computers which can be scaled depending on the processing load and database size.
[468] The method and system of the present invention have been described above and in the attached drawings; however, modifications will be apparent to those of ordinary skill in the art and the scope of protection for the invention is to be defined by the claims that follow.

Claims

Claims:
1. Traveling seed amplifier system for continuous flow farming of material products, MP, comprising a plurality of N parallel mobile layers, for growing material specie from an initial seed mass, mi , and initial age, τ{ , to an amplified mass, Mf = Gsfhmi , at a harvest age, τ f , with an intrinsic specie seed to harvest time, rsth≡ rf - rf .
2. The system according to claim 1, further comprises a means for compressing said
T 1
intrinsic seed to harvest time by a compression factor given by atc≡—^-≡— .
sth N
3. The system according to claim 1, further comprises a means continuous planting at least one seed and synchronously harvesting at least one amplified initial mass replica, at a rate determined by; 1 / rh = N I rsth .
4. The system according to claim 1 , wherein the means for growing is accomplished by the continuous insertion of at least one initial mass layer, in at least one planting port and synchronous harvesting of at least one amplified mass layer from at least one harvesting port.
5. The system according to claim 2, wherein the means for compressing is accomplished by the continuous insertion of layers at input ports and subsequent transport of said layers for synchronous harvesting at harvesting ports.
6. The system according to claim 1, wherein the number of layers N is determined by, N = 2HSCTSA I hh , and wherein CTSA is a spatial compression factor, hh is the amplified plant height at harvest, hav , the average plant height, hav = hh l CTSA , and 2HS is the total distance traveled by all the layers.
7. The system according to claim 1 , wherein the material species include high plants, algae, microalgae, cyano-bacteria, fungi, or other material amplifying organisms.
8. The system according to claim 1, wherein the material products at least include: polysaccharides, biomass, lipids, sugars, starches, fruits, vegetables, seeds, cereals, alcohols, legumes, RNA, DNA, proteins, precursors for rubbers or other polymers, biofuel.
9. The system according to claim 1, wherein the material products are at least used for food, energy, medicines, industrial materials and specialty materials.
10. The system according to claim 1, wherein the parallel mobile layers move vertically.
11. The system according to claim 1, wherein the parallel mobile layers move horizontally.
12. The system according to claim 1, wherein, the initial seed mass is selected from at least one member of the group consisting of seeds, seedlings, plant cell culture, micro-organism culture, microalgae culture, bacteria culture, fungi culture, stem cuttings, root cuttings, leaf cuttings and eye cuttings.
13. The system according to claim 1, wherein amplified mass is harvested at the vegetative phase of the plant growth trajectory.
14. The system according to claim 1, wherein amplified mass is harvested at the stationary phase of the plant growth trajectory.
15. The system according to claim 1, wherein the parallel mobile layers comprise at least a handle structure and at least one tray comprising a least one string of SGE.
16. The system according to claim 1, wherein the parallel mobile layers comprise at least a handle structure and at least one tray removable attached to said handle structure.
17. The system according to claim 1, wherein the parallel mobile layers comprise at least a handle structure and at least one disposable tray.
18. The system according to claim 1, wherein the parallel mobile layers comprise at least one string interconnected to move vertically.
19. The system according to claim 1, wherein the parallel mobile layers comprise at least one string interconnected to move horizontally.
20. The system according to claim 1, wherein the parallel mobile layers are permeable to resources that include: light, nutrients, gases, fluids, biomass, shoots, and roots.
21. The system according to claim 1, wherein the interlayer spacings of parallel mobile layers are compressed by means of allowed overlap of shoots and roots of at least one neighboring layer.
22. The system according to claim 1, wherein the interlayer spacings of parallel mobile layers are compressed by means of the TSA automated variable interlayer spacing adjuster design algorithm
23. The system according to claim 1, wherein the interlayer spacings of parallel mobile layers are compressed by means space-saving compactness of the integrally made multifunction SGEs.
24. The system according to claim 1, wherein the parallel mobile layers comprise at least one string interconnected to move vertically.
25. The system according to claim 1, wherein the parallel mobile layers comprise at least one string interconnected to move horizontally.
26. The system according to claim 1, wherein the number of layers, N, is designed to be in the ranges: 2-10, 10-100, 100-1000, and 1000-10,000.
27. The system according to claim 1, wherein the parallel mobile layers comprise trays that interconnected to form multi-layer three dimensional array structure disposed in a first, second and third spatial coordinates.
28. The system according to claim 27, wherein the array structure is periodic, in at least one spatial coordinates direction, and wherein the periods are in the ranges: 10-100 micron; 100- 1000 microns, 1-10 mm, 10-100 mm, and 100-1000 mm.
29. The system according to claim 27, wherein the layer and tray have thickness values in the ranges: 10-100 micron; 100-1000 microns, 1-10 mm, and 10-100 mm.
30. The system according to claim 1, wherein the number the gain Gsth may have values in the ranges of 2-10, preferably 10-1000, more preferably 1000-100,000, for cell cultures, and even more preferably 100,000 to 100 million.
31. The system according to claim 1, wherein the initial mass «¾(!.) , may start at any temporal position, τ{ , on the growth trajectory, including τ{ = 0 , or kt i = yktTsfh , where γ may be in the range of 0-0.1, or 0.1-0.2; or even 0.2-0.5.
32. The system according to claim 1, wherein the intrinsic species dependent seed to harvest time, rsth , ranges from 1-10 hours, or 10 hours to 10 days, or 10 days to 1000 days, and initial mass M^r,.) , may start at any temporal position, ^ , on the growth trajectory, including rt = 0 , or ktTi = yktTsfh , where^ may be in the range of 0-0.1, or 0.1-0.2; or even 0.2-0.5.
33. A High Density Multi-Layer Farming System comprising at least one integrally made SanSSoil growing element, SGE.
34. The system as in claim 33, wherein the SGE comprises a means to provide multifunction self-sufficiency to sustain life of said biomass.
35. The system according to claim 33, wherein said at least one SGE is interconnected to form multi-laye three dimensional array structure disposed in a first, second and third spatial coordinates.
36. The system according to claim 33, herein said at least one SGE comprises:
at least one biomass containment structure,
at least one biomass feeding structure integrally connected to said containment structure, and,
one joining substructure in communication with at least one source to sustain biomass life.
37. The system according to claim 33, wherein the integrally made SGE is disposed in the direction of a first spatial coordinate and the bio-mass growth axis is in a direction forming an angle relative to said first spatial direction.
38. The system according to claim 33, wherein the bio-mass comprises the root, stem and shoot systems growing in a direction a long a growth axis that makes an angle from 0 to 90 degrees with respect to said first spatial coordinate direction.
39. The system according to claim 34, wherein the multi-functions are selected from the group consisting of mechanical support, nutrient delivery and biomass growth.
40. The system according to claim 34, wherein the multi-functions further comprise at least one function selected from the group consisting of seed germination, illumination, oxygen and carbon dioxide conduction, humidity control, temperature controls and sensing function.
41. The system according to claim 35, wherein the array structure comprises:
at least one string disposed in a first spatial coordinate direction comprising:
a plurality of interconnected SGE separated by a first set of plurality of spaces along the first spatial coordinate,
at least one source for providing multi-functions to support biomass growth to said SGE.
42. The system according to claim 41 , wherein the first set of plurality of spaces comprises identical spaces of a first spatial period along a first spatial coordinate direction.
43. The system according to claim 41, wherein said at least one string comprises a plurality of strings disposed in a first plane along a first and second spatial coordinate directions, and wherein plurality of strings are separated by a second set of plurality of spaces.
44. The system according to claim 43, wherein the second set of plurality of spaces comprises identical spaces of a second spatial period along a second spatial coordinate direction.
45. The system according to claim 43, wherein said plurality of strings disposed in said first plane, further comprises a sources of multi-function to support growth and a structure to mechanically support said plurality of strings.
46. The system according to claim 35, wherein the array structure comprises: a plurality of strings of interconnected integrally made SGE disposed in a plurality of substantially parallel plurality of planes, wherein, the planes are along the first and second spatial coordinates, and separated by a third set of plurality of spaces, along a third coordinate direction.
47. The system according to claim 46, wherein the third set of plurality of spaces comprises identical spaces of a third spatial period along a third spatial coordinate direction.
48. The system according to claim 47, wherein the array structure comprises, a plurality of self-sufficient interconnected SGE, forming a three dimensional multi-layer periodic structure comprising, first, second and thirds spatial periods.
49. The system according to claim 48, wherein each of first, second, and third spatial periods may be varied during the growth time trajectory of the bio-mass.
50. The system according to claim 48, wherein the array structure further comprises: means for mechanical support structure,
and at least one source for providing for multi-functions, and,
a housing structure for containing the system.
51. The system according to claim 48, wherein array comprises a plurality of strings of integrally made SGE intercommoned in a network of an appropriate series and parallel connecting arrangements.
52. The system according to claim 46, wherein said plurality of planes comprises, strings along a first spatial coordinate which is the vertical direction.
53. The system according to claim 34, wherein, the biomass is phototrophic organism.
54. The system according to claim 34, wherein, the biomass is phototrophic microorganism.
55. The system according to claim 34 wherein, the biomass is at least a phototrophic plant.
56. The system according to claim 34, wherein, the biomass is phototrophic bacterium.
57. The system according to claim 34, wherein, the biomass is algae.
58. The system according to claim 34 wherein, the biomass is a living organism.
59. The system according to claim 34 wherein, self-sufficiency comprises essential nutrients.
60. The system according to claim 59 wherein, essential nutrients comprise primary nutrients, secondary nutrients, and trance elements.
61. The system as in claim 36 wherein, the containment structure further comprises: perforations to allow roots and fluid to pass there through.
62. The system as in claim 36 wherein, the containment structure further comprises: at least one substructure for supporting biomass and growing media.
63. The system as in claim 62 wherein the growing media comprises: soilless gel.
64. The system as in claim 62 wherein the growing media comprises: soilless mesh structure.
65. The system as in claim 62 wherein the growing media comprises: soilless fiber structure.
66. The system as in claim 36 wherein the feeding structure further comprises: a nutrient delivery substructure integrally connected to containment structure.
67. The system as in claim 66wherein said nutrient delivery substructure comprises: spraying function.
68. The system as in claim 66 wherein said nutrient delivery substructure comprises: misting function.
69. The system as in claim 66 wherein said nutrient delivery substructure comprises: dripping function.
70. The system as in claim 66 wherein said nutrient delivery substructure comprises: fogging function.
71. The system as in claim 36, wherein, the feeding structure is a closed tubular structure.
72. The system as in claim 36, wherein the feeding structure is an open structure.
73. The system as in claim 36, wherein, the at least one joining substructure comprises: a quick connect/disconnect feature for communication with at least one source to sustain biomass life.
74. A Permeable 3D Multi-Layer Farming System comprising at least one integrally made SanSSoil growing element, SGE, and at least one means to provide resource permeability.
75. The system in claim 74, wherein the SGE comprises a means to provide multifunction self-sufficiency to sustain life of said biomass.
76. The system according to claim 74, wherein said at least one SGE is interconnected to form multi-layer three dimensional array structure disposed in a first, second and third spatial coordinates, wherein the system further comprises at least one means of resource permeability.
77. The system according to claim 76, wherein the array structure comprises:
at one layer comprising a network of interconnected strings SGE wherein said at least layer is permeable to shared resources.
78. The system according to claim 76, wherein the shared resources include, illumination, heating, cooling, and nutrients.
79. The system according to claim 76, wherein the array structures comprising at least a first and second layers and a space there between, wherein the plant roots of first layer shares the space of the plant shoots of the second layer.
80. The system according to claim 76, wherein the array structures comprising at least a first and second layers and a space there between, wherein the plant shoots of the second layer, shares the space of the plant roots and shoots of the first layer.
81. The system according to claim 76, wherein the array structures comprising at least a first and second layers and a vertical space there between; and a means for compression of vertical space, wherein said means comprises layer construction so as to enable the sharing roots and shoots of plants in first and second layers.
82. The system according to claim 76, wherein the array structures comprising at least a first and second layers wherein said structures are constructed from sustainably transparent material permeable to light from at least one source.
83. The system according to claim 76, wherein the array structures comprising at least a first and second layers wherein said layers are permeable to fluids from at least one source.
84. The system according to claim 83, wherein said fluids are delivered by at least one subsystem selected from the group consisting of fogging, misting, streaming and dripping.
85. A SanSSoil farming system for photosynthetic growth of organisms, comprising:
a protected SanSSoil environment for sustaining the growth of at least one plant specie, to produce at least one product; and
a means for controlling said environment to maximize the economic viability index, EVI: the photosynthetic conversion efficiency multiplied by the gain factor; wherein said gain factor is selected from the group: { g„ gml, g,gml } .
86. The system according to claim 85, wherein said means to maximize EVI comprises at least the control ofg, .
87. The system according to claim 85, wherein said means to maximize EVI comprises at least the control ofge .
88. The system according to claim 85, wherein said means to maximize EVI comprises at least the control of gegsol .
89. The system according to claim 85, wherein said means to maximize EVI to at least a value ranging between 0.1 and 1.0.
90. The system according to claim 85, wherein said means to maximize EVI to at least a value of 1.
91. The system according to claim 85, wherein said means to maximize EVI to at least a value ranging between 1 and 10.
92. The system according to claim 85, wherein said means to maximize EVI to at least a value larger than 0.05.
93. The system according to claim 85, wherein said means to maximize EVI comprises the control of the gain factor to a value larger than 1, preferably between 1 and 10.
94. The system according to claim 85, wherein said means to maximize EVI comprises the control of the gain factor to a value between 10 and 100.
95. The system according to claim 85, wherein said means to maximize EVI comprises the control of the gain factor to a value between 100 and 1000.
96. The system according to claim 85, wherein said means to maximize EVI comprises the control of the gain components selected from the group: {g^G^ } .
97. The system according to claim 85, wherein said means to maximize EVI comprises the control of the gain components selected from the group: {G Gt,Gf } .
98. The system according to claim 85, wherein said means to maximize EVI comprises the control of at least one gain component gf in the group represented by the product function n
§Φ = Y[ g, = gm§ I giigenVgBrg photon wherein each member gl represents a maximum in the =1
optimum value range of said member of the group, and wherein the members represent elements necessary to sustain and products plant product.
99. The system according to claim 98, wherein said elements are groups necessary to sustain and enhance plant product selected from the group consisting of gm = gco gH 0g0
Si ~ SNSPSK SlI ~ SsScaS gS n £cu £ env ~ £ soilS pH £τ £ weather £ pest
£ photon £ λ£ t£ sp '
100. The system according to claim 85, wherein said means to maximize EVI comprises the control of the RCR multiplied by EVI to a value larger than 1 , more preferably larger than 2, and most preferably larger than 3.
101. The system according to claim 85, wherein said at least one specie is a whole plants.
102. The system according to claim 85, wherein said at least one specie is a photosynthetic organism.
103. The system according to claim 85, wherein said at least one specieis photosynthetic microorganism, including algae and cyano-bacteria, and other carbon dioxide assimilating microorganisms.
104. The system according to claim 85, wherein said at least one product is food humans and animals.
105. The system according to claim 85, wherein said at least one product is plant derived fuel.
106. The system according to claim 85, wherein said at least one product is plant derived proteins , vaccines, nutraceuticals, and pharmaceuticals.
107. The system according to claim 85, wherein said at least one product is plant derived material for industrial use and for personal care products.
108. The system according to claim 85, wherein sustaining growth includes controlled nutrients delivery to maintain values for each nutrient within predetermined optimum quantity range, avoiding costly and toxic overdose, and maximizing biomass productivity.
109. The system according to Claim 108, wherein nutrient delivery includes at least one means of delivery selected from the group consisting of a first fogging system, a second fogging system, foliar feeding, root uptake feeding, pulsed feeding, and sequential switching from one means to another.
1 10. The system according to claim 85, wherein sustaining growth includes optimum delivery of light by means including: pulsed illumination at intensities not to exceed the saturating level to maximize temporal gain factor and avoid photorespiration losses.
111. The system according to claim 85, the protected SanSSoil environment includes means to construct said environment to be impervious to pests, microbes, uncontrolled fluids, gases, and particulates.
112. The system according to claim 85, the protected SanSSoil environment includes means to shield and insulate the interior from the uncontrolled fluctuating temperatures.
113. The system according to claim 85, the protected SanSSoil environment includes means to prevent admission of UV, infrared, and portions of the visible spectrum that prevents growth under uncontrolled conditions.
114. The system according to claim 85, the protected SanSSoil environment includes an enclosure, and load-lock systems to enable the sterilization of personnel, and the ingredients essential for plant growth.
115. The system according to claim 85, the protected SanSSoil environment comprises structures suitable for plant growth, wherein said structures do not include soil.
116. The system according to claim 85, the protected SanSSoil environment comprises three dimensional structures comprising at least one SanSSoil growth layer, comprising at least one SanSSoil Growth Element, SGE, wherein said three dimensional structures, at least one layer and SGE, are so designed for maximum space utilization efficiency.
117. The system according to Claim 1 16, wherein said three dimensional structures, at least one layer and SGE, are so designed to allow maximum light utilization efficiency by means of constructing said structures using optical transparent materials .
118. A SanSSoil method for indoor growing plants and other photosynthetic organisms comprising the steps of:
a. providing a substantially impermeable environment;
b. providing at least one growth layer capable of sustaining growth of plant a plant specie, and comprises at least on integrally made SGE;
c. providing seeds to be germinated in at least one SGE to establish a seedling that is viable for further growth, or alternatively, providing at least one seedling that is fixed in an SGE to adapt and become viable for further growth;
d. providing light having optimized wavelength, intensity, and temporal characteristics; selecting a program stored in the control system that comprises optimized temporal steps, and parameter values for the plant specie, which is designed to give an optimum growth trajectory for the desired product;
e. activating the control system to start the growth protocol for the desired specie;
f. monitoring the growth conditions by means of sensors to enable the control system make adjustments, as needed, follow the designed growth trajectory; g. harvesting the products;
h. repeating the cycles for either batch mode culture or continuous culture.
19. The SanSSoil method of claim 118 further comprises the steps of:
n
varying the parameters in EVI " = ge¾ = (GspGtGf )(Y[ ;
=1
establishing the optimum range, minimum and maximum values for each for each parameters;
recording and storing said optimum ranges for each species;
providing a program which incorporates said optimum ranges and established the growth trajectory for each species that leads to harvesting the desired product;
loading said program into system controller;
commanding a programmed system controlled to execute steps (a) through (g).
PCT/US2014/036754 2013-05-05 2014-05-05 Soil-less indoor farming for food and energy production, including high density three dimensional multi-layer farming, permeable three dimensional multi-layer farming and continuous flow farming of material products WO2014182600A1 (en)

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US13/887,334 US20140325908A1 (en) 2013-05-05 2013-05-05 High Density Three Dimensional Multi-Layer Farming
US13/887,333 US9606553B2 (en) 2013-05-05 2013-05-05 SanSSoil (soil-less) indoor farming for food and energy production
US13/887,337 2013-05-05
US13/887,337 US20140325910A1 (en) 2013-05-05 2013-05-05 Traveling Seed Amplifier, TSA, Continuous Flow Farming of Material Products, MP
US13/887,336 2013-05-05
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US13/887,336 US20140325909A1 (en) 2013-05-05 2013-05-05 Permeable Three Dimensional Multi-Layer Farming

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