Organic Fuels Presentation Naa 2008 04 10
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Algae Oil Extraction Thomas E. Gieskes © Organic Fuels Holdings, Inc. - All rights reserved
March 2008
1
Organic Fuels
•
Houston based producer of biofuels • Operating 55 MM GPY biodiesel plant on Houston Ship Channel since January 2006 • Projects in development for ethanol from biomass and sugarcane • Biodiesel feedstock integration into palm, jatropha and algae
•
For algae, focus is on developing oil extraction technologies
© Organic Fuels Holdings, Inc. - All rights reserved
March 2008
2
Algae Processing Options Cultivation
Conditioning
Harvesting
Concentration
Preparation
Extraction
Open Pond
Filtration
Centrifuge
Mechanical
• Ambient Air CO2 • Enhanced CO2
• Belt • Closed
• Primary • Secondary
• Extruder • Expeller Press • Steam Explosion
Drying
Stressing
Closed System
• Nutrients • Residence Time
• Enhanced CO2
1 - 3 g/l 10 - 20% lipids
• No Drying • Ambient Air • Heated
Gravity • Flotation • Settling
1 - 3 g/l 20 - 40% lipids
© Organic Fuels Holdings, Inc. - All rights reserved
50 - 100 g/l 20 - 40% lipids
Filter Press
Chemical
• Continuous Belt • Batch Operation
• Solvent • Super Critical CO2
60 - 80% DM 20 - 40% lipids
80 - 90% DM 20 - 40% lipids
95% recovery 95% lipids
March 2008
3
Oil Extraction Challenge •
•
© Organic Fuels Holdings, Inc. - All rights reserved
Microscopic algae suspended in water are virtually indestructible •
Incompressible microscopic balloons suspended in an incompressible medium
•
Cell wall and membrane have a high elasticity modulus
•
Even when free water has been removed, wet biomass retains sufficient interstitial water to act as lubricant
Rupture of cell wall through mechanical friction and steam explosion is only possible when dry
March 2008
4
Extraction Energy Balance Water 998 kg Water 38 kg
Free Water 10 kg Cell Water 8 kg
Free Water 0 kg Cell Water 4 kg
2 kg DM
2 kg DM
2 kg DM
Water 4 kg
1 cubic meter
Algal Biomass 2 kg DM
• • •
Oil 0.8 kg Meal/Protein 1.2 kg
Cultivation
Harvesting
Filter Press
Drying
Extruder
0.5 kWh/kg DM
0.25 kWh/kg DM
0.25 kWh/kg
4.5 kWh/kg DM
0.5 kWh/kg
Total energy usage in conventional cultivation, harvesting and dry extraction can be as high as 20,000 kJ/kg Dry Matter Energy contained in DM is 0.4 kg oil @ 34,000 kJ/kg + 0.6 kg Meal/Protein @ 16,000 kJ/kg = 23,200 kJ/kg DM Drying accounts for 75% of energy usage
© Organic Fuels Holdings, Inc. - All rights reserved
March 2008
5
Design Considerations • Energy intensive process steps • • • • • •
Water circulation and make-up water supply CO2 compression for closed photo-bioreactors Biomass concentration Biomass drying Extrusion/Steam Explosion Solvent recovery and circulation
• If not optimized, can reduce overall energy efficiency to less than 50% • Use and disposition of algal meal and protein also plays an important role in overall energy efficiency
© Organic Fuels Holdings, Inc. - All rights reserved
March 2008
6
Organic Fuels Approach • Partnered with University of Texas at Austin under Sponsored Research Agreement • Focus on oil extraction from algae and other cellular materials • Process reduces energy usage by 75% when compared with conventional dry extrusion • Current status • Principles proven, experiments confirm theory • Preliminary patents filed • Currently expanding to semi-commercial scale
© Organic Fuels Holdings, Inc. - All rights reserved
March 2008
7
OF Algae Process Configuration Light
Oil Cultivation 1 - 3 g/l
CO2
Harvesting 50 - 100 g/l
OF/UT Process
Self Cleaning Centrifuge
Meal Water
Nutrients
• With complete cell destruction, oil, meal and water can be separated by centrifuge or settler/clarifiers • Avoids use of organic solvents with their associated safety and environmental problems • Meal and protein options when retained in watery phase: • • •
Fermentation to alcohol, making CO2 available for recycle Anaerobic digestion to methane for power production and effluent recycle Food source for aquaculture (fish, shrimp, etc.)
© Organic Fuels Holdings, Inc. - All rights reserved
March 2008
8
Path Forward • Joint Venture formed with UT to commercialize technology • Venture open to participation by strategic partners with complimentary technology components • Expect to see multiple pathways in emerging technology field • Broad range of cultivation and harvesting techniques • Effectiveness of extraction and processing technologies will largely depend on site specific factors, i.e., ambient air drying, fresh versus salt water cultures, etc.
• Next two to three years are going to be exciting, with potential for algae oil to be commercially available before first crops of currently planted Jatropha and other perennial energy crops with long lead times © Organic Fuels Holdings, Inc. - All rights reserved
March 2008
9
March 2008
1
Organic Fuels
•
Houston based producer of biofuels • Operating 55 MM GPY biodiesel plant on Houston Ship Channel since January 2006 • Projects in development for ethanol from biomass and sugarcane • Biodiesel feedstock integration into palm, jatropha and algae
•
For algae, focus is on developing oil extraction technologies
© Organic Fuels Holdings, Inc. - All rights reserved
March 2008
2
Algae Processing Options Cultivation
Conditioning
Harvesting
Concentration
Preparation
Extraction
Open Pond
Filtration
Centrifuge
Mechanical
• Ambient Air CO2 • Enhanced CO2
• Belt • Closed
• Primary • Secondary
• Extruder • Expeller Press • Steam Explosion
Drying
Stressing
Closed System
• Nutrients • Residence Time
• Enhanced CO2
1 - 3 g/l 10 - 20% lipids
• No Drying • Ambient Air • Heated
Gravity • Flotation • Settling
1 - 3 g/l 20 - 40% lipids
© Organic Fuels Holdings, Inc. - All rights reserved
50 - 100 g/l 20 - 40% lipids
Filter Press
Chemical
• Continuous Belt • Batch Operation
• Solvent • Super Critical CO2
60 - 80% DM 20 - 40% lipids
80 - 90% DM 20 - 40% lipids
95% recovery 95% lipids
March 2008
3
Oil Extraction Challenge •
•
© Organic Fuels Holdings, Inc. - All rights reserved
Microscopic algae suspended in water are virtually indestructible •
Incompressible microscopic balloons suspended in an incompressible medium
•
Cell wall and membrane have a high elasticity modulus
•
Even when free water has been removed, wet biomass retains sufficient interstitial water to act as lubricant
Rupture of cell wall through mechanical friction and steam explosion is only possible when dry
March 2008
4
Extraction Energy Balance Water 998 kg Water 38 kg
Free Water 10 kg Cell Water 8 kg
Free Water 0 kg Cell Water 4 kg
2 kg DM
2 kg DM
2 kg DM
Water 4 kg
1 cubic meter
Algal Biomass 2 kg DM
• • •
Oil 0.8 kg Meal/Protein 1.2 kg
Cultivation
Harvesting
Filter Press
Drying
Extruder
0.5 kWh/kg DM
0.25 kWh/kg DM
0.25 kWh/kg
4.5 kWh/kg DM
0.5 kWh/kg
Total energy usage in conventional cultivation, harvesting and dry extraction can be as high as 20,000 kJ/kg Dry Matter Energy contained in DM is 0.4 kg oil @ 34,000 kJ/kg + 0.6 kg Meal/Protein @ 16,000 kJ/kg = 23,200 kJ/kg DM Drying accounts for 75% of energy usage
© Organic Fuels Holdings, Inc. - All rights reserved
March 2008
5
Design Considerations • Energy intensive process steps • • • • • •
Water circulation and make-up water supply CO2 compression for closed photo-bioreactors Biomass concentration Biomass drying Extrusion/Steam Explosion Solvent recovery and circulation
• If not optimized, can reduce overall energy efficiency to less than 50% • Use and disposition of algal meal and protein also plays an important role in overall energy efficiency
© Organic Fuels Holdings, Inc. - All rights reserved
March 2008
6
Organic Fuels Approach • Partnered with University of Texas at Austin under Sponsored Research Agreement • Focus on oil extraction from algae and other cellular materials • Process reduces energy usage by 75% when compared with conventional dry extrusion • Current status • Principles proven, experiments confirm theory • Preliminary patents filed • Currently expanding to semi-commercial scale
© Organic Fuels Holdings, Inc. - All rights reserved
March 2008
7
OF Algae Process Configuration Light
Oil Cultivation 1 - 3 g/l
CO2
Harvesting 50 - 100 g/l
OF/UT Process
Self Cleaning Centrifuge
Meal Water
Nutrients
• With complete cell destruction, oil, meal and water can be separated by centrifuge or settler/clarifiers • Avoids use of organic solvents with their associated safety and environmental problems • Meal and protein options when retained in watery phase: • • •
Fermentation to alcohol, making CO2 available for recycle Anaerobic digestion to methane for power production and effluent recycle Food source for aquaculture (fish, shrimp, etc.)
© Organic Fuels Holdings, Inc. - All rights reserved
March 2008
8
Path Forward • Joint Venture formed with UT to commercialize technology • Venture open to participation by strategic partners with complimentary technology components • Expect to see multiple pathways in emerging technology field • Broad range of cultivation and harvesting techniques • Effectiveness of extraction and processing technologies will largely depend on site specific factors, i.e., ambient air drying, fresh versus salt water cultures, etc.
• Next two to three years are going to be exciting, with potential for algae oil to be commercially available before first crops of currently planted Jatropha and other perennial energy crops with long lead times © Organic Fuels Holdings, Inc. - All rights reserved
March 2008
9
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