WO2016013025A2

WO2016013025A2 - Photo-bioreactor design for low cost algae biodiesel

Info

Publication number: WO2016013025A2
Application number: PCT/IN2015/000295
Authority: WO
Inventors: Prakash Tarun KUMAR
Original assignee: Kumar Prakash Tarun
Priority date: 2014-07-25
Filing date: 2015-07-22
Publication date: 2016-01-28
Also published as: WO2016013025A3

Abstract

The invention aims to produce biodiesel from micro-algae at low cost to replace the hydrocarbon fuels by modifying the design of conventional photo-bioreactor to increase its capacity for algae growth and increase the yield at minimal cost. By changing the design of photo-bioreactor; making it in form of long triangular structure with rectangular boxes present at each side of the triangle has provided more space for the cultivation of algae at minimal cost. The invention will consist of three photo-bioreactors one above the other with slanting side present at a varying angle of 30-60 depending upon the sunlight falling on the area; connected via pumps and pipes to ensure continuous flow of algae water and consist of long reflectors long the side of photo-bioreactor to reflect sunlight onto them. The solar panels on each side of the photo-bioreactor provide sufficient energy required to run the machinery. The reuse of byproducts during the products has reduced the overall cost.

Description

Photo-Bioreactor Design for Low Cost Algae Biodiesel

Field of Invention:

This invention aims to reduce the dependence on hydrocarbons for fuelling our

transportation and energy sector by producing biodiesel from microalgae which is a renewable source of energy at low cost by using a modified design of photo-bioreactor. This invention relates to increase the yield of algae biodiesel and use the byproducts and other renewable technologies to make the cost of production low.

Prior Art:

Our dependence on Hydrocarbons for fuelling our transportation sector and energy sector threatens our energy security, affecting our environment and weakening the economy. These hydrocarbons are soon going to be depleted and we need another alternative source to fuel our energy sector and continue developed. The only alternative was renewable based fuels called biofuels. So I thought to work to produce biodiesel for our future generation and reduce carbon footprints, knowing that the fossils fuels are depleting very fast. They are nonrenewable and in near future they will get depleted and our development will stop. Their prices are also increasing very fast. We assume that their prices would be more than gold and platinum in the near future. First and second generation biofuels derived mainly from plants are not capable of replacing the demand of hydrocarbon fuels. So the third generation of biofuels from microalgae was brought to use. But many problems came up with algae biodiesel like high cost of production, not utilizing the natural resources properly and no profits in business revenues. Therefore their use was limited to small scale but it was a promising solutio to replace hydrocarbons. By modifying design we hope to produce algae biodiesel at low cost. Objective of Invention:

The primary objective of the invention is to develop a low cost renewable fuel to replace the current hydrocarbons which are non-renewable and cause extreme harm to the environment.

The secondary objective is to improve the design of the photo bioreactor so as to increase the yield at minimal cost by utilizing the natural resources efficiently.

Further the objective is to reduce the overall production cost by utilizing the byproducts in profitable way and devising a profitable business model with this invention; while ensuring less harm occurs to the environment.

Summary of Invention:

This invention aims to reduce the high cost of algae biodiesel production and overcome the difficulties present in the current production method. The current designs of photo

bioreactors are inefficient as the cost of production of biodiesel associated with them are relatively high; due to which their use is limited. They do not utilize the area available to them efficiently, which can result in increase of their yield. Also they don't utilize the natural resources properly and the byproducts are not used in innovate way which results in the increase in production cost. We need a solution to this problem as the need for nonrenewable energy source is on rise because the hydrocarbon based fuels are going to be depleted soon.

This invention of modified photo bioreactor uses microalgae to produce biodiesel as it can be easily grown in any part of world with just basic nutrients due to its unicellular or simple multicellular structure. It donsist of three levels of photo bioreactor; each level with 4 system for growing algae. This indention includes solar panel system to generate electricity for the machinery and uses long reflectors placed on both sides of the photo bioreactor to reflect sunlight onto the photo bioreactors,

This invention helps to reduce our dependence on hydrocarbons by providing an alternative source of fuel. The major advantage of this invention is that it helps to reduce the harm on environment caused by hydrocarbons and combat problems like air pollution, Global warming. This invention mainly reduces the cost of production of algae biodiesel, which would help common people as they would save a lot of money on diesel by using biodiesel. By using this invention on large scale, we could provide jobs to millions of people, which would indirectly help the country's economy and also increase the standard of living of people. It utilizes the land and natural resources in a highly advantageous way. rief Descriptions of the Drawing:

The seven sheets completely illustrate the model of the invention.

Sheet 1 depicts the front view and titled view of the modified design of the photo bioreactor without the pumping system in two figures.

Sheet 2 has three figures; two depicting the side view and front view of the solar panels placed on the side of photo bioreactors and third figure depicts the pumping system which will be attached to the front and back of photo bioreactors.

Sheet 3 has three figures; two depicted the side and front view of the reflectors placed at bottom of photo bioreactors and third figure depicts the front view of the photo bioreactor with the pumping system.

Sheet 4 shows the side view of .the three levels of photo bioreactor system, with solar panels and pumping system.

Sheet 5 shows the vie from middle of the levels of photo bioreactor system constructed on large scale. ' . ^'

Sheet 6 depicts the top view of the reflectors placed at a certain^distance from bottom of the photo bioreactor system.

Sheet 7 depicts the front view of the photo bioreactor system of all levels, with the pumping system and reflectors.

Detailed Description of the Invention:

This invention of modified photo, bioreactor increases the capacity of algae growth by using different systems for their cultivation, reducing the risk of contamination and providing higher capacity at minimal, cost. This invention consist of three levels of photo bioreactor; each level with 4 system for thtir growth. It includes solar panel system on each side of photo bioreactor to utilize the sunlight - a renewable energy source, to generate electricity for the machines required to run tie photo bioreactor and other processing units needed.

The invention consists of pumps at each level and system which are interconnected so as to keep the continuous pumping of algae so as to maintain their growth proper. It uses long reflectors placed on both sides of the photo bioreactor so as to focus sunlight onto the reactors which would help to increase the yield the growth of algae. The invention of photo bioreactor consists of mechanism to provide essential nutrients for the growth of algae, a pipe system to bubble carbon dioxide regularly so to get more productivity. The reactor made of transparent glass allows sunlight properly to fall on the algae. The reactor is in a shape of triangle with rectangular boxes at each side of the triangle which provides more space for growing algae at minimal cost. The two sides of the triangle excluding the base are at an angle of 30-60 degree depending on the angle of sunlight falling on the area, and length of an average of 20meters and width of 1.5 meters; with rectangular box of depth of a foot

The detail of the invention. is illustrated in the drawings consisting of 7 sheets.

On sheet 1, fig. 1 and fig.^■¾ depicts the design of photo-bioreactor modified to increase the algae growth capacity at minimal cost.

No.l depicts the stands which will support the three levels of photo bioreactors which will be made from a low cost metal. The stand will be round in shape and connected to rectangular boxes present at base of each level. The stand will be place at a distance of 3-5 meters.

No.2 depicts the rectangular box present at base of each level of photo-bioreactor constructed in form of pyramidal structure. The box will contain algae water where the algae will be cultivated. The box length will be an average of 20m , height of 30-45cm and width about 2- 3 meters. The box will be made of transparent glass and will not consist solar panels.

No.3 & No.4 depicts the slanting sides of photo-bioreactor. These will also be rectangular boxes with measurement mentioned for No.2 Box. These boxes will be present at a varying degree of 30-60 depending on the amount and angle of sunlight falling on the area where the plant will be constructed. There will be 3 rows of solar panels placed on them at appropriate distance to allow sufficient amount of sunlight to fail on algae water present inside the photo-bioreactor. *^■ .

No.5 depicts the main storage 5f the. photo-bioreactor where algae will be cultivated. This is major part. The water level will depend on the amount of sunlight. Also the angle would vary from 30-60 degree.

No.6 depicts the solar panels in rectangular form of 3 rows will be placed on side of the photo-bioreactor of No.3 & No.4 boxes. They will be placed at equidistant from each other and at sufficient space to allow maximum amount of sunlight to fall on the algae so we are able to maintain their growth. ^'

No.7 depicts the connection of solar panels will be connected to energy unit of the production plant which will generate electricity enough to run our machinery and extra amount of electricity would be send to villages. On Sheet 2, solar panel system which will be energy unit of our plant so we ensure we are independent on electricity source and we are able to reduce our cost of production; and major pumping system which will ensure the continuous flow of algae and provide specific nutrients and carbon dioxide required for their growth.

Fig. 3 depicts the front view of solar panels. There will be 3 levels of solar panels as shown in no.6. No.6 shows the solar panels placed at equidistant from each other so to allow maximum amount of sunlight to fall on the algae so as to get high yield.

Fig. 4 depicts the side view of solar panels placed on the slanting sides of photo-bioreactor.

No.7 shows the connections of solar panels.

Fig. 5 shows the pumping system.

No.8 is the major pumping section of the plant. It will be connected to each level and each box where algae will be grdwn. They will ensure continuous flow of algae water. They will have various pipes for inlet and outlet which will be interconnected.

Also these pumps will provide nutrients required for their growth through the inlet valves present in the pipes and carbon dioxide required for the respiration process of the algae.

No.9 depicts the major pipe connected to box 5.

No.10 depicts pipe connected to box No. 4

No. 11 depicts pipe connected to box no. 3

No.12 depicts pipe connected to box No .2

These all pipes will be interconnected via pump and keep continuous pumping of algae from one box to another. There will be inlets at each of them for nutrients and carbon dioxide.

No.13 depicts the outlet pipe which will either bring the fresh algae water which needs to be cultivated or the matured algae.which needs to be harvested. They will be connected to each level pump and directly to -harvesting unit.

In sheet 3, the front view of the pumping system which will be present at each level. Fig 6 and Fig 7 depicts the reflectors present at each side of photo-bioreactor system to reflect more amount of sunlight onto them to maximize yield. Fig. 6 depicts the side view -of reflectors.

No.14 is the reflectors which will be of same length of the photo-bioreactor system. Its width will depend on the amount of sunlight. For smaller amount of sunlight, the width will be longer and vice versa. They are in form of rectangles made from high quality reflecting material.

No.15 is the stand which will support the reflector and the motor required to turn them.

No.16 depicts the motor connected to middle of the reflector. They will be responsible for turning the reflectors depending upon the sunlight falling on them. This will ensure maximum amount of sunlight falls on the photo-bioreactor.

Fig 8 depicting the pipes connected to the photo-bioreactor.

No.8 depicts the pumping system.

No.9 depicts the major pipe connected to box 5.

No.10 depicts pipe connected to box No. 4

No. 11 depicts pipe connected to box no. 3

No.12 depicts pipe connected to box No.2

No.13 is the outlet pipe. ^* .

In sheet 4, Fig. 9 depicts the side view of the photo-bioreactor system and pumping.

No.8 ; the pumps are shown how they will be connected to each level of photo-bioreactor .

ϋί;

No.13 is the outlet pipe connected to each pipe. They are connected to harvesting unit. No.l is the stand to support the photo-bioreactor.

No.6 shows how the solar panels will be placed on each level of photo-bioreactor on their each side.

On sheet 5, Fig. 10 depicts how the plant will look with each level of photo-bioreactor system and many constructed together. No.17 together depicts the three levels of photo-bioreactor.

On sheet 6, Fig. 11 depicts¾ow the reflectors will be used along the side of photo-bioreactor system.

No.14 is the reflectors placed at a particular angle so as to reflect maximum amount of sunlight onto the No.17 which are the three levels of photo-bioreactor.

On sheet Ί, fig 12 depicts the front view of the three levels of photo-bioreactor system.

No.13 is the outlet pump connected to each level.

No.14 is the reflectors placed at each side of the photo-bioreactor.

This project can be even used as a business , as it not only helps to reduce pollution and stop global warming but also, help to develop a country's economy , increase its GDP , provide employment to many people and make profits for the company.

i

For eg. Normal biodiesel costs about 60rs. Per liter and my biodiesel costs rs 48 per liter after adding profit. So if a person drives 10000km annually with mileage 15km/l , his bill would be 40,000rs. But if he uses biodiesel, his bill would be 32,000rs , so he saves 8000 annually. Also company will earn a good profit, and as time passes with development of more technologies and more technologies will be which will lower the cost of production. This project could be started anywhere in the world, with any investment as it would give 25% return annually on an average. This invention will produce millions of jobs and help develop economy. .

* '

This invention could provide biomass, electricity and water to farmers in rural areas for agricultural purposes. Already many farmers in India are facing problems water shortage due to less rainfall which has reduced the production of food grains in our country due to which thousands of people die annually. Also the face electricity shortage and use fertilizers and pesticides which has degraded the quality of food grains which also lead to many deaths. But with my project and through its byproducts it won't happen so. We would provide the fresh water, biomass and electricity which would help them farming all the year and increase their production. This would ensure that there is no shortage of food shortage and electricity would help in running their machinery. Also they will use the biomass which is organic which would help to remove the toxic particles from the food grains and thus we would get a healthy food. So we would not only produce biodiesel at low cost but also develop agricultural sector, which in turns help to develop the country. Method of performing Invention:-

The modified design of photo-bioreactor has helped to produce biodiesel from micro-algae at low cost with an increase yield . The basic method is to cultivate algae, harvest them and produce oil from lipids present in the micro-algae. Then the algae's oil is transformed to produce biodiesel using basic chemicals. The electricity generated from solar panels is used to run the machinery.

Firstly we are required to set up photo-bioreactor which is the main part of the production for algae biodiesel. Then other machinery Algae Harvesting Unit, Processing Unit; Energy Unit and other small units required^'for functioning using the funds from government and private investors.

The photo-bioreactor which is triangular in shape will be placed in 3 nos. one above the other each other connected via pumps and pipes required for continuous flow of algae during their cultivation. Reflectors will be placed along the side of the photo bioreactors at the ground to reflect the sunlight onto them. Solar Panels will be placed on each side of the photo-bioreactor to generate.electricity. The photo-bioreactors will be made of transparent glass and slanting sides varying from 30-60 degree according to the sunlight falling on the area. -

After setting up the photo-bioreactor, the other units will be set up to complete the plant.

For the first day, Algae water is put into the photo-bioreactor in each system of the reactor. Pumps will be pumping continuously to ensure flow. Nutrients like Sodium, Potassium, Phosphorus and other fertilizers required to grow the type of algae present; Carbon dioxide will be continuously pumped into the reactor which are required for the growth of algae. At the end of 3^rd day the algae when it will be frilly matured they would be processed further. The fully grown algae will be processed in harvesting unit where the oil will be extracted from lipids from the algae. After the oil is extracted it will be processed using trans esterification process. The oil will be mixed with ethanol/methanol and sodium

hydroxide/potassium hydroxide. After the process is completed, we get two layers one of impure biodiesel and glycerin. Glycerin will be sent to other industries at a specific rate to earn profit which is our by product. Impure Biodiesel is sent for further purification where it will be purified using hot and distilled water. The pure biodiesel formed now will be sent directly to use.

The Biomass left over can be used in biogas plant to produce biogas and the water extracted in harvesting unit will be recycled again.

The solar panels will generate electricity to run the machinery, and the extra energy will be sent to villages. »' .

Claims

Claims:

1. An apparatus designed for producing biodiesel by cultivating algae in a modified

design of photo bioreactor; comprising of solar panel system for generating electricity from solar energy; different system of photo bioreactor to get more yield from limited area; reflectors at bottom of photo bioreactor to reflect sunlight onto reactor and pumping system for continuous supply of nutrients and algae throughout the system.

2. The invention consists of a modified design of photo bioreactor system for the

cultivation of algae which has led to increase the yield and decrease the overall cost of production of algae biodiesel to replace hydrocarbons and making it a viable option for use.

3. The apparatus described in claim 1, comprises of three level of photo-bioreactor one above the another; each level with different system so as to reduce the risk of contamination and many such levels will be built over a vast are to grow algae for the production of algae biodiesel.

4. The apparatus described in claim 1, includes four different systems on each level that is the three rectangular boxes placed at each side along the length of the main triangular system where the algae will be cultivated. The description of each side is as follows:

(a) The slanting sides will be present at a varying angle of 30-60 degree

depending on the amount of sunlight which are the base angles of the

triangular systems

(b) Each system will be made from transparent glass so as to allow maximum

sunlight to fall on the algae growing inside the reactor.

(c) The sides of each, system will depend on the angle and amount of sunlight falling on the area where a-lg^'ae wi.ll be cultivated so as to maximize the yield.

5. The apparatus described in claim 3, will consist of pumps and pipes at each level of photo bioreactor for:

(a) Continuous pumping of algae water from one system to another.

(b) Provide essential nutrients and carbon dioxide required for the growth of algae.

(c) Providing algae water which is to be cultivated from 1^st day or the matured algae which is to be taken^" for harvesting after 3^rd day.

6. The apparatus described in the claim 1, includes long reflectors made from high quality reflecting material placed on both sides of the photo bioreactor at ground so as to focus sunlight onto the reactors; including a motor to turn the reflectors according to the angle of sunlight falling on that area.

7. The apparatus described in claim 1, comprises of solar panel system placed at

equidistant from each other at slanting sides of photo bioreactor system at each level to generate electricity from sunlight to run the machinery.

8. In the apparatus described in claim 1 , all the by-products left during the process will either by reused or sold to other industries to gain profits.

9. The apparatus described in claim 1, includes stands made from strong metallic

material to support each level of photo bioreactor placed at equidistant from each other.