1st InteSusAl Workshop on Sustainable Microalgae …intesusal-algae.eu/.../05FCC_aqualia_Workshop_InteSusal_.pdf · 1st InteSusAl Workshop on Sustainable Microalgae Biomass Production

1st InteSusAl Workshop on Sustainable Microalgae Biomass Production

From Lab Tests to Industrial Scale

Olhão, 21st May 2015

PhD, ZOUHAYR ARBIB

Coordinator, WP: Cultivation, harvesitng and design DEMO

WP: Biomass plant

WP: Biogas Upgrading

WP: Biodiesel

Fleet vehicle

WP: LCA


OBJECTIVES

Targets: •Industrial scale 10 ha •Produce Biofuel for vehicles •Avoid consumption of fossil fuels

Specific Targets of All-Gas

• Low cost culture medium N and P in wastewater

• Low cost photobioreactor

• Algae growth + Anaerobic digetion

• design of sustainable units


First steps before `growing´

Site location

Requirement

Water

El Torno WWTP

10000m3/d

30 Hect

Climatic conditions

Land

No Freshwater

Non arable land


Scale up

Scale up…. Necessary!!!

Phase I

Basic

research


Scale up


Phase I

2010

Basic

research

Pilot plant

200m2


Scale up


Phase I

2010

2011-2013

Basic

research

Pilot plant

200m2

Prototype

1000m 2


Scale up


Phase I

2010

2014-2015

2011-2013

Basic

research

Pilot plant

200m2

Prototype

1000m 2

DEMO I

3.6 Hect


Scale up


Phase I Phase II

2010

2011-2013

2014-2015

2015-2016

Basic

research

Pilot plant

200m2

Prototype

1000m 2

DEMOII

10Hect


Scale up


Phase I Phase II

2010

2011-2013

2014-2015

2016


All-gas concept : first approach

Bacteria

O2

CO2

Microalgae WW rich in C, N and P

Energy value of WW 4.2kWh/kgCOD!!!!


All-gas concept : Second approach

Bacteria

O2

CO2

Microalgae UASB

Biomethane 200LCH4/kg COD

50% C, Same N and P

C, N and P

Dewatering

Effluent

Green wastes

Solar dryer

Oil extraction

biodiesel

UASB HRAP

Anaerobic digestor

Boiler

CO2 CO2

CH4

CO2

CH4

WW

Exhaust gas CO2

Dewatering

Algae biomass

Alternative B

Alternative A

Bacteria CO2

To gas station

Heat

Solar dryer

CH4 + CO2

Biogas


All-gas: final approach

Harvesting

CH4


All-gas Instalation: PILOT plant- 200m2

6 X 3 m2 HRAP 6 X 32 m2 HRAP

Harvesting skid 6.5 m3 settler

DAFAST

3X 20 m3 UASB

Coagulation

Floculation

Sulfide removal

CH4 stripping

Gas holder

WW pretreatment Cultivation and harvesting


All-gas Instalation: PILOT plant results- 200m2

Cultivation and WWT

0

10

20

30

40

50

g V

SS

/m2

d

HRT 7 HRT 3HRT 5 HRT 5

0

2

4

6

8

10

12

14

P-P

O4

3-(m

g/L

)HRT 7 HRT 5 HRT 3 HRT 5

0

20

40

60

80

100

N-N

H4

+(m

g/l

)

HRT 7 HRT 5 HRT 3 HRT 5

Average 73 Ton/ha yr

Average 20 gSVV/m2d

Objective 100 Ton/ha yr


All-gas Instalation: PROTOTYPE main elements- 1000m2

Hydraulic improvment

Mechanical improvment

0.6 to 0.8W/m2

Low hydraulic

performance <20%

LEAR A 25 cm/s0.1W/m2 A 30 cm 0.2W/m2

Raceway pond Vs Low Energy Algae Reactor



Harvesting

•High separation process (>95 % TSS)

•Wide range of concentrations (200-1000 mg/L)

•Low energy consumption 0.04kWh/m3

• Coagulants (Metal Salts Al o Fe) and flocculant

(polielectrolite) is needed

20 m3/h DAFAST

Plug flow floculatros

From 250 to 400 mg TSS/L

to 40,000 to 55,000 mg TSS/L

Concentration factor 125 to 160

30 to 40 Wh/m3



Biomass thermal recovery

ANAEROBIC DIGESTERS

DIGESTATE 3-4%TSS

POLYMER DOSING

DECANTER CENTRIFUGE PIERALISI BABY I

DIGESTATE 15-20%TSS

DRY BIOMASS 70-85%TSS

SOLAR DRYER HUBER BABY I

SOLAR CAPTORS GREEN WASTE

+CO2

1000m2 RACEWAYS PONDS

LIPIDS

+ HEAT

+ HEAT

25 kW boiler

2 X 600L 1X 1500L


All-gas Instalation: PROTOTYPE final flow diagram-1000m2

2 X 500 m2 DAFAST 20m3/h

Anaerobic digesters

2 X 600L 1X 1500L

Decanter

+ heat

+ heat


All-gas Instalation: PROTOTYPE results- 1000m2

Cultivation and WWT

0

10

20

30

40

25-Feb 07-Mar 17-Mar 27-Mar 06-Apr 16-Apr 26-Apr

P (

g V

SS/m

2d

)

LEAR PDW

0

10

20

30

40

50

60

25-2 17-3 6-4 26-4 16-5

TN (

mg/

L)

IN EF DAFAST

0

3

6

9

25-2 17-3 6-4 26-4 16-5

P-P

O4

(m

g/L)

IN EF DAFAST


All-gas Instalation: PROTOTYPE results—1000m2

Bioenergy production

Mesophilic (35ºC) 175 L CH4/kg VSS

Thermophilic (55ºC) 250 L CH4/kg VSS

Similar to Activated sludge biomass

Pretreatment Cell disruption

•Ozonization

•Thermal hydrolisis

•Biological/Enzimatic Hydrolisis

•Chemical

Raw biomass

Thermal pretreatment Biochemical Methane Potential

X 2


All-gas Instalation: DEMO I- 3.6 Hect

Raceways 7X 5186 m2 unit

DAFAST 30 2X 110 m3/h

Anaerobic digesters 2000 m3

Biomass boiler 200kW

Biogas Upgrading plant

Gas-Station

VW fleet


All-gas Instalation: DEMO 10 hectare energy balance

-0,79

-0.23

1.5

0,49

-0,79 -0.52

1,83

0.52

Electricity Heat Biomethane Net Balance

kWh th/m3

MESOPHILIC THERMOPHILIC

Meso versus Thermo

14.7%

27.1%

15.6% 14.6%

27.9% Electricity imputs

Initial pumping, UASB and grit removal

HRAPs

Harvesting

Digestion

Biogas upgrading and compression

Cultivation and harvesting 42.7 %

Biogas upgrading and compression At 250 bar

Average net energy balance 0,50 kWh th/m3

0

0.2

0.4

0.6

0.8

1

Electric EnergyConsumed

Electric EnergyProduced

kWh

/m3

Conventional Wastewater Treatment Plant CHP

0

0.2

0.4

0.6

0.8

1

Electric EnergyConsumed

Electric EnergyProduced

kWh

/m3

All-gas process

•1600 kgAlgae/d •260 kg CH4/d 20000 km/yr 5 kgCH4/100 km 100 cars/yr moved with Biomethane

1000 m2

1 car

Prototype target sept 2015


All-gas Instalation: 10 hectare balance

24

Special session for algae cluster &

guided visit to All-gas instalation


From Lab Tests to Industrial Scale

``It is not love or money that makes the world go round, it

is photosynthesis´´

(Mosojidek, Koblizek and Torzillo, 2004)

Documents

1st InteSusAl Workshop on Sustainable Microalgae …intesusal-algae.eu/.../05FCC_aqualia_Workshop_InteSusal_.pdf · 1st InteSusAl Workshop on Sustainable Microalgae Biomass Production