Stream/Description Component Composition (kg/day) Mass % metric ton1 CO2 13114388 12.01 13114

Scrubbed N2 85148050 78.01 85148flue gas O2 3274925 3.00 3275

CO 10371 0.01 10NOX*** 40937 0.04 41

SO2 131 0.0001 0.13CXHY 6550 0.01 7H2O 7561802 6.93 7562Total 109157153 100.00 109157

Stream/Description Component Composition (kg/day) Mass % metric ton2 CO2 2312788 1.31 2313

Exhaust gas with N2 85148050 48.26 8514890.81% CO2 removed O2 11154972 6.32 11155and all NOX CO 10371 0.01 10assumption: no water NOX 0 0 0vapor is picked up SO2 131 0.0001 0.13in the exhaust. CXHY 6550 0.004 7all O2 in CO2 leaves H2O 77808380 44.10 77808in this stream Total 176441242 100 176441

Stream/Description Component3 Sunlight

Just to stress the factthat it is crucial to the process, this stream issunlight

Stream/Description Component Composition (kg/day) Mass % metric ton4 Calcium 13018 0.04 13.0

This stream is the Iodine 27 0.00 0.03nutrient stream, which Iron 7657 0.02 7.7contains an aqueous Magnesium 18552 0.05 18.6nutrient solution. Phosphorus 52717 0.15 52.7

Zinc 4182 0.01 4.2Nitrogen 10577 0.03 10.6

H2O 35754553 99.7 35754.6Total 35861283 100.0 35861

Stream/Description Component Composition (kg/day) Mass % metric ton/day5 H2O 39839742 100.0 39840

make-up water

Stream/Description Component Composition (kg/day) Mass % metric ton/day6 H2O 3498608147 100.0 3498608

recycled water fromthe sand filters

Stream/Description Component Composition (kg/day) Mass % metric ton/day7 algae 5891802 0.17 5892

algae and water H2O 3501133205 99.83 3501133total 3507025007 100.0 3507025

Objective

Why micro-algal biodiesel?

Process Flow Sheet Extraction

Biodiesel

Economics

References

Algae Production

This section is where the oil is separated from the algae via continuous bed extraction and subsequent evaporation and distillation stages. Algae enters with 3 wt% moisture from the algae toasters. The overall Extraction mass balance is presented below. The Extraction Process is modeled after the Crown Iron Works Soy Crush Process.

1.National Biofuel Action Plant. Rep. Oct. 2008. U.S department of Energy. Apr. 2009 <http://www1.eere.energy.gov/biomass/pdfs/nbap.pdf>.

2.Macleod, Claire S., Adam P. Harvey, Adam F. Lee, and Karen Wilson. "Evaluation of the activity and stability of alkali-doped metal oxide catalysts." Chemical Engineering Journal 135 (2008): 63-70.

3.Chisti, Yusuf. "Biodiesel from microalgae." Biotechnology Advances 25 (2007): 294-306.

45%

20%

20%

10%5%

ProteinFatCarb.FiberMin./Vit.

Figure 2. Composition Chart of Chlorella sp.

Chlorella Oil content is typically 28 – 32 percent of dry mass

Plant Layout

Slurry Input

Extraction Section

Steam Input

Algae Output

Oil Output

Condensate Output

Current National Fuel ChallengesAmerica has one-third of the world’s automobiles (230 million) and uses twenty-five percent of the world’s oil.The Energy Information Administration projects that reliance on foreign producers for oil will increase 30% through 2030. Our transport sector’s greenhouse gas emissions will grow by nearly 40% through 2030.

Figure 1. U.S. petroleum production capacity and demand

A promising solution to this challenge is to use biodiesel derived from algae as a transportation fuel. The objective is to design a biodiesel production facility that will grow enough algae to produce a 10,000 BPD gasoline energy equivalency in biodiesel. This facility has the capability to grow and process the algae and convert its fatty lipids into biodiesel. This facility will be next to a coal power plant, where flue gas from the plant will be scrubbed and then bubbled into the algae growing raceway ponds. The CO2 rich flue gas will significantly increase algal growth, greatly reducing the amount of ponds needed.

One benefit of microalgae is its oil yield per land area. Table 1 shows that microalgae has the best oil yield per area. There is not even enough farmable land in the U.S. to produce 50% of US transport fuel needs with 3 of the above crops. Algae is the only source of fatty lipids that has the potential to replace oil derived transport fuels in the near future. Additionally, algae will not use valuable farm land.

Chlorella sp. will be the algae that the model is based upon.

The Axens’ Esterfip-H process has significant advantages over the traditional process:

•Higher Yield•High Quality Glycerin

•98% Pure•No soap formation•100% Biodiesel yield

Flow rate Inlet Outlet Inlet Outlet

(kg/h) reactor 1 reactor 1 reactor 2 reactor 2

Methanol 62217 55747 62217 59729

Glycerin 0 5600 622 1867

Methyl ester 0 58858 57489 61595

Monoglycerides

0 2240 2240 995

Diglycerides 0 1244 1244 249

Oil 62217 747 622 0

Total 124435 124435 124435 124435

Temperature (C)

170-250 170-250

Pressure (atm) 30-70 30-70

Table 1. Comparison of different sources of biodiesel

Extraction Inlet (lb/hr) Outlet (lb/hr)

Algae 541250 405461

Water 11046 11046

Oil 0 135789

Steam 108342 0

S. Condensate 0 108342

Total 660638 660638 Photo-

bioreactor

Pump (raceway pond)

De-gaser

Solar tube

Pump (solar tube)

Scrubbed Flue Gas

vent

Raceway Pond

Dirty Flue Gas

Paddle Wheel

Pump (FDSF) FDSF #1

Pump(storage tank)

Scrubber

Power Plant

Flue Gas Blower

Water/limestone

Water/limestone/SO2

Water/limestoneStorage Tank

Water/limestoneSO2 Storage

Tank

Pump (Scrubber)

Pump (Scrubber)

Tractor 1

To Extraction Unit

Nutrient Tank

Water/Nutrient

Nutrient to PBRNutrient to RWP

Flue Gas Out

Make up Water

CO2 used (metric ton/day)

NOX used (ton/day)

10801.6 40.94

Capi tal Cost $ Operational Cost $/yrEqui pment + i nstal l at i on Mai ntenance + Servi ce 20, 729, 451. 98$ PBR - Nutri ent 952, 291. 00$ Pumps 216, 000. 00$ Chemi cal sExcavati on 124, 707, 812. 69$ CaCO3 2, 047, 650. 00$ Rei nforce concrete 29, 186, 972. 70$ Make-up Water 13, 790, 216. 45$ Asphal t 299, 901, 366. 00$ PVC 57, 469, 581. 20$ scrubber 175, 000, 000. 00$ Al gae Toaster 4, 500, 000. 00$ Bui l di ng 690, 000. 00$ Land 2, 867, 200. 00$ Paddl e Wheel 103, 226, 400. 00$ Total 797,800,000.00$ Total 37,600,000.00$

Capi tal Cost $ Operational Cost $/yrEqui pment + i nstal l at i on 24, 000, 000. 00$ Mai ntenance + Servi ce 720, 000. 00$ Storage 75, 000. 00$ Chemi cal sChemi cal s Hexane (Make up) 665. 75$ Hexane 133, 149. 00$ Mi neral Oi l (make up) 50. 00$ Mi neral Oi l 16, 240. 00$ Total 24,300,000.00$ Total 800,000.00$

Capi tal Cost $ Operational Cost $/yrEqui pment + i nstal l at i on 119, 521, 084. 00$ Mai ntenance + Servi ce 3, 585, 632. 52$ Storage 500, 000. 00$ Chemi cal sExcess Methanol (recycl e) 10, 651. 62$ Methanol 15, 710, 900. 78$ Total 120,100,000.00$ Total 19,300,000.00$

Capi tal Cost $ Operational Cost $/yrCool i ng Tower 1, 110, 000. 00$ Mai ntenance + Servi ce 33, 300. 00$ Bol i er 1, 300, 000. 00$ Mai ntenance + Servi ce 39, 000. 00$

Natural Gas & Water treat. 11, 652, 480. 00$ El ectri c 50, 053, 269. 13$ Labor 6, 496, 000. 00$

Total 2,500,000.00$ Total 68,300,000.00$ $ $/yr

Total Capi tal Cost 944,700,000.00$ Total Operational Cost 126,000,000.00$

Exctrati on Uni t cost

Biodiesel pl ant cost

Other

Algae Producti on Uni t Cost

Revenue per yrBi odi esel 443802 (gal / day) 2. 44 ($/ gal ) 395, 250, 061Gl ycerol 342397 ( l b/ day) 0. 5 ($/ l b) 62, 487, 453Burn Al gae Cake 53522 (MMBtu/ day) 1. 26 ($/ MMBtu) 24, 614, 768Carbon Credi t 0 0 -$ N Ox Credi t 0 0 -$ Total 482, 400, 000. 00$

Reactor 1 Reactor 2

Triglyceride feed(from Extraction Unit)

Partial Evap.

Settler Settler

Partial Evap.

Full Evap

Drier

condensor

Knock out Drum

Distillation column

Vaccum evaporator

condensor

Settler

Coalescer

Methanol Feed

Glycerin > 98%

Methyl Ester >99%

summary

in (metric ton) 3683466 out (metric ton) 3683466

Payback Period

$-

$1,000

$2,000

$3,000

$4,000

$5,000

$6,000

0 2 4 6 8 10 12 14 16 18

Years

US

D $

(M

illio

n)

Capital

Cum. Net Operating Income

IRR = 24%