Industrial application of microalgae in the circular ... Industrial application of microalgae in the

Industrial application of microalgae in the circular bioeconomy Dorinde Kleinegris

[Applied Biotechnology / Microalgae]

Why microalgae?

• High areal productivity

• CO2 mitigation

• No arable land

• Low water use

• Seawater and wastewater

• Can use residual streams for nutrients

• High diversity, many products

[Applied Biotechnology / Microalgae]

CO2

Nutrients (N, P)

+ O2

[Applied Biotechnology / Microalgae]

Products with algae inside

Lipids 20 %

Proteins 50 %

Carbohydrates 20 %

Pigments 3 %

Ashes 7 %

Nannochloropsis

https://www.google.nl/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRxqFQoTCO2l5f7Hg8gCFcqSLAodgvMC3w&url=https://nuts.com/chocolatessweets/m-m/&psig=AFQjCNEnuC73uLxoupkgvUMWAfCZNzILJQ&ust=1442768052038042 http://www.google.nl/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRxqFQoTCN6p3cmIhMgCFcbdLAodHA0EzQ&url=http://www.newtrition.basf.com/web/global/newtrition/en_GB/product_portfolio/index&psig=AFQjCNH3jnyJlxhILihCZilFc7uC6AnHEw&ust=1442785366141304

There is a large gap

[Applied Biotechnology / Microalgae]

CommoditiesMicroalgae

Commercial production: challenges

[Applied Biotechnology / Microalgae]

Product costs

Scale

Production chain analysis

Market development

Biomass Production costs: Model

Netherlands

Saudi Arabia

Canary Islands

Turkish Riviera

South Spain

Curacao

Culture temperature

Daily Dilution

Mixing day/night)

Operation days per year

...

Light Intensity

Electricity costs

Taxes

Labor € / Kg biomass

CAPEX & OPEX

NER

Sensitivity Analysis

Areas to focus

Output

Location

Cultivation

System

Empirical data

Specific

parameters

Input

Product costs - biomass production

[Applied Biotechnology / Microalgae]

Projections 100ha

Cost breakdown: cultivation costs

[Applied Biotechnology / Microalgae]

Sensitivity analysis

[Applied Biotechnology / Microalgae]

Biomass composition: benchmark on Nannochloropsis

N-replete N-limited

Lipids 20% 50%

S F

A *

M U

F A

*

P U

F A

*

S F

A *

M U

F A

*

P U

F A

*

Glyco-, Phospho-lipids 12% 35% 30% 35%

10% 45% 40% 15%

Triacylglycerides 2% 37.5%

Waxes 3% 1.25% Sterols 3% 1.25%

Proteins 50% 30% Water soluble 20% 12%

Non-water soluble 30% 18%

Carbohydrates 20% 15%

Monosaccharides 5% 3% Polysaccharides 15% 12%

Pigments 3% 1%

Ashes 7% 4%

Microalgae

Lipids

Proteins

Waxes Sterols

Cosmetic Health care

Biopolymer

Surfactants

Biolubricant

Paint, Coating

TAG Glyco-lipids

Phospho-lipids

Soluble proteins

Un-soluble proteins

Pharma

Bulk chemicals

Food additives

Food/Feed

Biodiesel Biokerosene Bioethanol Biobutanol Biomethane

Carbohydrates

Mono- Oligo- saccharides

Starch Cellulose

M a rk

e t d

e m

a n

d

S e llin

g p

ric e

Ash/minerals

Pigments Chlorophyll Carotenoid Phycobilins

Microalgal biorefinery

Microalgal biorefinery design and techno-economical analysis

Biomass productivity

Biomass composition

Utilities cost

(energy, labour)

Mass and energy balances

CAPEX

OPEX

Microalgal biomass

Disrupted Biomass

Hexane

Isopropanol

Polar lipids

TAG

Pigments

Waxes

50 C

1 bar

Hexane

Isopropanol

Water

Water

Ash

non water soluble proteins

proteins

carbohydrates

0.4 bar

I.1) BEADM ILLING

III.1) LIPID EXTRACTOR III.2) DISTILLATION COLUM N

FOR SOLVENT RECOVERY III.3) DECANTER FOR

WAXES REM OVAL

2 C

III.4b) BLEACHING FOR PIGM ENT REM OVAL

IV.1) DIAFILTRATION FOR

PROTEINS WASHING

IV.2) SPARY DRIER

FOR PROTEINS/CARBOHYDRATES

Waxes

Steam

Pigment

Polar lipids

TAG

III.0) SPRAY DRIER

Proteins

Carbohydrates

Ash

Microalgal biorefinery design and techno-economical analysis

Food/feed

Microalgal biorefinery design and techno-economical analysis

Biofuel

P-14 / R-101

Stoich. Reaction

Microalgal biomass

Disrupted Biomass

Hexane

Isopropanol

Polar lipids

TAG

Pigments

Waxes

50 C

1 bar

Hexane

Isopropanol

FAME

Glycerol

Pigments

Sterols

NaOH

Methanol

Methanol

NaOH

Water

Water

Ash

non water soluble proteins

Proteins

Carbohydrates

Ash

2 bar

60 C

30 min

0.4 bar 0.4 bar

Water FAME

Sterols

Pigments

Glycerol

H3PO4 Na3PO4

I.1) BEADM ILLING

III.1) LIPID EXTRACTOR III.2) DISTILLATION COLUM N

FOR SOLVENT RECOVERY III.3) DECANTER FOR

WAXES REM OVAL

2 C

III.4) BATCH REACTOR

FOR TRANSESTERIFICATION

III.5) EVAPORATION/CONDENSATION

FOR M ETHANOL RECOVERY

III.6) EXTRACTOR FOR

GLYCEROL WASHING

IV.1) DIAFILTRATION FOR

PROTEINS WASHING

IV.2) SPRAY DRIER

FOR PROTEINS/CARBOHYDRATES

Waxes

III.0) SPRAY DRIER

Proteins

Carbohydrates

Microalgal biorefinery design and techno-economical analysis

P-14 / R-101

Stoich. Reaction

Microalgal biomass

Disrupted Biomass

PEG

PEG

water soluble Proteins

Polysaccharides

Monosaccharides

Phosphate

PEG

Hexane

Isopropanol

Polar lipids

TAG

Pigments

Waxes

50 C

1 bar

Hexane

Isopropanol

FAME

Glycerol

Pigments

Sterols

NaOH

Methanol

Methanol

NaOH

Water

Water

Ash

non water soluble proteins

non water soluble proteins

non water soluble proteins

Ash

2 bar

60 C

30 min

0.4 bar

0.4 bar

water soluble Proteins

Polysaccharides

Monosaccharides

Phosphate

PBS buffer

Monosaccharides

water soluble Proteins

Water FAME

Sterols

Pigments

Glycerol

H3PO4 Na3PO4

1 kDa

Phosphate

II.1) DIRECT PROTEIN

EXTRACTOR

I.1) BEADM ILLING

II.2) BACKWARD PROTEIN

EXTRACTOR II.7) DIAFILTRATION UNIT FOR

PROTEINS/POLYSACCHARIDES

FRACTIONATION II.3) ULTRAFILTRATION UNIT FOR

PROTEIN/POLYSACCHARIDES

CONCENTRATION

II.9) SPRAY DRIER FOR POLYSACCHARIDES

Polysaccharides

II.4) ULTRAFILTRATION UNIT

FOR PHOSPHATE RECOVERY

II.6) SPRAY DRIER

FOR PHOSPHATE CONCENTRATION

III.1) LIPID EXTRACTOR III.2) DISTILLATION COLUM N

FOR SOLVENT RECOVERY III.3) DECANTER FOR

WAXES REM OVAL

2 C

III.4) BATCH REACTOR

FOR TRANSESTERIFICATION

III.5) EVAPORATION/CONDENSATION

FOR M ETHANOL RECOVERY

III.6) EXTRACTOR FOR

GLYCEROL WASHING

IV.1) DIAFILTRATION FOR

PROTEINS WASHING

IV.2) SPRAY DRIER

FOR PROTEINS

1 kDa 300 kDa

Waxes

10 kDa

Water

II.10) SPRAY DRIER FOR WATER SOLUBLE PROTEIN

II.8) DIAFILTRATION UNIT FOR

PROTEINS/M ONOSACCHARIDES

FRACTIONATION

Complete biorefinery

Biorefinery costs

Cost breakdown

Biorefinery costs

Market value of biomass

Market value of biomass

€ 3.4

+

€ 0.9

€ 4.3

€ 3.4

+

€ 1.1

€ 5.5

€ 3.4

+

€ 0.9

€ 4.3

€ 3.4

+

€ 2.9

€6.3

€ 3.4

+

€ 2.9

€ 6.3

€ 3.4

+

€ 3.0

€ 6.4

Cultivation costs

South of Spain

Biorefinery costs

Total costs

Market value of biomass

€ 3.4

+

€ 0.9

€ 4.3

€ 0.5

+

€ 1.1

€ 1.6

€ 0.5

+

€ 0.9

€ 1.4

€ 3.4

+

€ 2.9

€6.3

€ 3.4

+

€ 2.9

€ 6.3

€ 3.4

+

€ 3.0

€ 6.4

Cultivation costs