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Algae Photobioreactor Design Considerations for Commercial

Scale Production

Presented by:Greg Karr

State of the Industry(Algae Farming)

Current

Future

Traditional Farming: 50 – 70 years Algae Farming: 5-7 years (so far)

1930’s Farming or 2009 Algae

Current• Crops can and are

grown and harvested• Require high inputs per

yield, labor/energy• Large scale operations

not feasible or even possible

Future • Equipment improvements will

increase yields and decrease production costs

• Production methods will continually be refined and made more efficient

• Biotech will drive yields up and increase value of specific products

Assumption: Algae industry stays alive

Open Pond

• Lower tech, well known technology

• Lower capital costs• Lower operational and

maintenance costs

• Limited ability to control•Temperature (low side)•Species selection•Seasonal flucuations•Evaporation losses

• Lower production rates, yields and product value• Production rates and product values do not offset costs (under normal conditions)

MRI Florida raceway open pond

Closedloop PBR’s

• Higher tech, generally unproven

• Much higher capital costs• Higher operational costs

and maintenance costs• Offers higher level of

control•Temperature (low side)•Species selection•Evaporation losses

• Offers potential for higher production rates and higher value products• Billion $ question: Can the higher production rates ever justify the extremely large capital and operational costs?

MRI KC AlgaeLink PBR, 3500 L

Capital CostsUnit basis ($ cost/$ revenue)

Higher

Investment Risk

Land Usage

Light Collection

Service Life

Production Controls

Productivity

Product Value (species selection)

Lower

Operational CostsUnit basis ($ cost/$ revenue)

Higher

Labor

Maintenance

Utilities

Water source

Growth Nutrients

Gas input (source and energy)

Culture Maintenance

Lower

Revenues

Adding Value

Biomass Combustion

Animal Feed

Algal Oil

Liquid Biofuel Feedstocks (starches/celluloses)

High Value Compounds

Waste reduction (water/fertilizers)

CO2 mitigation

Lower Value

Issues Not Discussed Here

• Harvesting – All current methods are less than ideal

• Governmental Influences– Subsidies – Regulation

• Energy Market Fluctuations• Competing Technologies• Implications of GMO algal species

What is the optimal PBR Design Balance?

Answer: It depends

• Regional and site specific• Variable input characteristics• Must be ready to adjust and make trade offs to

achieve the most profitable system possible.

Questions?