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Subitec GmbH: our company profile Basics of microalgae cultivation Our product: the Flat-Panel Airlift (FPA) Photobioreactor Pilot plants The current situation and future perspectives
Microalgal biotechnology
Vision
On the basis of the globally patented flat-panel airlift photobioreactors, designable algae biomass can for the first time be produced on an industrial scale with a low consumption of resources.
Company profile
Spin-off of the Fraunhofer Institute for Interfacial Engineering and Biotechnology (IGB) in Stuttgart Two patent families regarding the Flat Panel AirliftPhotobioreactors granted worldwide Pilot plants with E.ON Hanse AG (in Hamburg) and EnBW AG (near Stuttgart) since 2008 Numbers of employees: 6
Systems for the cultivation of microalgae based on 5 L, 30 L und 180 L-FPA photobioreactors R&D partner for biorefinery concepts based on algae biomass Production of algae biomass for the cosmetic and pharma industry and for product development Development of cultivation processes for the production of lipid-rich algae
Agar culture
flasks
10L bottles
FPA photobioreactors
50 mL 0 1
200 mL 4
500 mL 6 10
5L 14
30L 16
Customers needs
Roquette Soliance / KD-Pharma Cognis AG Carroux Innovation Scretting, BioMar CO2 Fixation Solvay E.ON AG EnBW AG Vattenfall Europe AG RWE Power AG Infinita Renovables SA
Bioenergy
Algafluid SA
FairEnergie GmbH
Pharmaceuticals / Cosmetics
Market volume
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Markets
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Subitec GmbH: our company profile Basics of microalgae cultivation Our product: the Flat-Panel Airlift (FPA) Photobioreactor Pilot plants The current situation and future perspectives
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Why Microalgae?
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Productivity per ha is 5 to 10-fold higher than for crops or other plants designable biomass Usage of CO2 from combustion processes Microalgae biomass is free of lignocellulose No competition with the production of food; no use of arable land for the microalgae cultivation Net energy production is possible High capital costs
2. Basics of microalgae cultivation 13
designable algae-biomass
Lipids
Proteins
Lipids
Carbohydrates
Pigments
Carbohydrate s
Proteins
Lipids
Carbohydrates
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Open ponds
Risk of contamination Volumetric productivity Cell density Energy input per volume Capital costs
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Energy content of algae biomass - energy input for cultivation _________________________ Net energy production
???
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80 60 40 20 0
Raceway pond
tubular PBRs
2. Basics of microalgae cultivation
FPA reactors
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Subitec GmbH: our company profile Basics of microalgae cultivation Our product: the Flat-Panel Airlift (FPA) Photobioreactor Pilot plants The current situation and future perspectives
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Problems: Inhibition of photosythesis Optimal light intensity is 5 to 10fold lower than the natural light intensity Limitation due to dense cultures
Solution: Continous transportation of the algal cells through the different zones Use of the flashing light effect
Light
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FPA technology
Halfshells of the FPA made from deep-drawn plastic sheets
Process engineering efficient light supply to all cells complete homogenious intermixing low mechanical stress to the cells simple temperature and pH control efficient gas exchange Cost-effectiveness high volumetric productivity high cell densities high reactor volumes low capital and operating costs high reliability
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Technical data:
270 cm 175 cm 5 cm
Volume Material
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Subitec GmbH: our company profile Basics of microalgae cultivation Our product: the Flat-Panel Airlift (FPA) Photobioreactor Pilot plants The current situation and future perspectives
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Project partner
EnBW AG
Site
Plant description
Culturing system for microalgae on the basis of 180 Liter Flat-Panel-Airlift Photobioreactors Total volume: 4.13 m (3 modules with 8 reactors each)
Start of operation
2008 4. Pilot plants
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4. Pilot plants
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Customer
E.ON Hanse AG
Site
Erdgasspeicher Hamburg-Reitbrook
Plant description
Culturing system for microalgae on the basis of 180 Liter Flat-Panel-Airlift Photobioreactors Total volume: 1,44 m (2 modules with 4 reactors each)
Scope of services
Planning, construction and technical assistence for the operation of a cultivation system for microalgae Use of flue gas from a CHP
Start of operation
May 2008
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Customer
FairEnergie GmbH
Site
Stadtwerke Reutlingen
Plant description
Culturing system for microalgae on the basis of 180 Liter Flat-Panel-Airlift Photobioreactors Total volume: 4.32 m (4 modules with 6 reactors each in a greenhouse)
Scope of services
Planning, construction and technical assistence for the operation of a cultivation system for microalgae Use of flue gas from a CHP
Start of operation
March 2010
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4. Pilot plants
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A short history of Subitec GmbH Basics of microalgae cultivation Our product: the Flat-Panel Airlift (FPA) Photobioreactor Pilot plants The current situation and future perspectives
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Other algae (sweet water) Chlorella vulgaris Chlorella sorokiniana Eigenisolat DSN 5.1 Haematococcus pluvialis 12 12 16 2,5a 5b Phaeodactylum tricornutum 25d 12e 0,8 1,3 0,7 0,5 0,3 1,5 0,9
inoculation
10 9 8 dry weight [g DW/l] 7 6 5 4 3 2 1 0 1.9.07 8.9.07 15.9.07 22.9.07 Date 29.9.07
production phase
2,50
1,50
1,00
0,50
Productivity
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Productivity per ha and year (t ODW / ha*a) Location tropical Mediterranean region central European Stuttgart Productive with 1g days per ODW/l*d year 365 300 240 200 137 113 90 75 with 0,8 g ODW/l*d 110 90 72 60
Estimated for 180 L type of FPA reactor with a 2.5 m distance between rows
For a 1 ha plant: capital costs 1,500,000 (25% for FPA photobioreactors) productivity 120 t / ha x year production costs: Depreciation Electricity Nutrients Personnel costs Total (incl. dep.) 2,000 200 1,500 500 4,200 / t ODW / t ODW / t ODW / t ODW / t ODW
Temperature control Lowering the energy input for the cultivation process Process automation Optimisation of the FPA photobioreactors Cost reduction of the culture media
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Development of new and more effective cooling systems Adaptation of greenhouse technology for algae cultivation
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Sterile filtration
ca. 150 mbar
Membrane
250 mbar
Water pressure
262 mbar
Exhaust gas
100 mbar
Algae biomass
Heat
District heat anaerobic digestion Filtrate Greenhouse Flue gas Ammonium Phosphate Concentrate Stripping / Precipitation
Biogas plant 500 kWel 5. The current situation and future perspectives 38
Network partners
Bundesland Baden-Wrttemberg
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