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World Biofuels MarketsRotterdam, Netherlands, March 22, 2011

World Biofuels MarketsRotterdam, Netherlands, March 22, 2011

How can we Scale-up Algae Production to Commercially

Viable Levels?

John R. Benemann, Consultant, Benemann Associates

and Director, Algal Biomass OrganizationWalnut Creek, California

jbenemann@aol.com

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Brief: Topics to be addressedBrief: Topics to be addressed

• …the latest developments in algae research, the newest harvesting, dewatering and modification techniques, and debate how the process can be scaled up.

• …identify product partners that ensure financial viability.

• …scale-up in terms of supply of nutrients, water and CO2.

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“The year was 1975, and my professor in Berkeley asked me if I wanted to change the world, and I said, sure, lets grow algae, that started it…”

ExxonMobil 30 sec TV spot, 2010-11

4ExxonMobil 30 sec TV spot, 2010-11

5ExxonMobil 30 sec TV spot, 2010-11

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“…the algae (cyanobacteria) will [be genetically modified to]secrete hydrocarbon fuels …”

ExxonMobil 30 sec TV spot, 2010-11

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WHY ALGAE BIOFUELS? HIGH YIELDS! – projectedWHY ALGAE BIOFUELS? HIGH YIELDS! – projected

Oil yields liters/ha-yr barrels/ha-yr

Soybeans 400 2.5

Sunflower 800 5

Mustard 1,600 10

Jathropha 2,000 13

Palm Oil 6,000 40

Microalgae 50,000*-250,000 300 - 1,500*maximum possible long-term yield, much above that is fantasy

no actual algae yields available, but are <10,000 liters/ha-yr (ExxonMobil in its PR releases states it aims at ~20,000 l/ha-yr]

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ExxonMobil TV Spot now banned in the U.K.ExxonMobil TV Spot now banned in the U.K.

March 9, 2011: …the ad stated "In using algae to form biofuels, were not competing with the food supply, and they absorb CO2, so they help solve the greenhouse problem as well". Because we understood that any CO2 absorbed by the feedstocks would eventually be re-released into the atmosphere,we concluded that the ad overstated the technology's total environmental impact and was therefore misleading. The ad breached BCAP Code rules 3.1 and 3.2 (Misleading advertising), 3.9 (Substantiation) and 9.5 (Environmental claims)

Action: The ad must not be broadcast again in its current form.

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Key Issues for Microalgae Biofuels to Debate:Key Issues for Microalgae Biofuels to Debate:• What production system: photobioreactors (vertical or

horizontal), ponds, hybrid, attached, mixotrophic* or ?

• What production process: continuous, semi-batch, two-stage (trigger oil synthesis), attached, milking, excretion ...

• What resources: CO2, water, climate, fertilizers, land …

• What co-products: animal feeds, wastewater treatment, chemicals (which?), food supplements, biogas, or ??

• What algae: green, diatoms, cyanos, or ? (see other talk!)* Mixotrophic: grown on light + sugars. I do not include dark

fermentations on sugars, that is a very different category …

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Spirulina

Dunaliella

Haematococcus

>100,000 species, infinite strains, all habitats

Chlorella

Cyclotella

Botryococcus

Microactinium>100,000 species, infinite strains, all habitats

11Roof of MIT Building~ 1950

Inoculum Tubes

Plastic bag-type photobioreactors (PBRs)

First algal mass culture project (for Chlorella)

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40 ha design based on 1950’s MIT rooftop plant40 ha design based on 1950’s MIT rooftop plant

Fisher (1956), A.D. Little Co. carried out an engineering design-cost estimate for a 40 hectare system of plastic tubes estimating (2008 $) capital cost >$1.25 million/ha Still pretty close to what we estimate now (best case)

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During the 1950s Prof. W.J. Oswald pioneered “high rate ponds” (HRPs) for low-cost waste water treatment and biofuels production : shallow, raceway, slowly mixed ponds (paddle wheel mixing intruduced in 1970s)

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THE KEY ISSUES IN MICROALGAE CULTIVATION ALREADY WELL UNDERSTOOD IN THE 1950s

THE KEY ISSUES IN MICROALGAE CULTIVATION ALREADY WELL UNDERSTOOD IN THE 1950s

• Production Systems: Ponds vs. photobioreactors • Productivity (solar conversion efficiency) g/m2-day or

tons biomass/hectare-yr, how to maximize (light dilution) • Oil production: very high content after N or Si limitation

BUT very low productivity – a still unresolved problem• CO2 sources (need), supply, transfer (a very dismal topic) • Mixing – why mix, how much to mix, what energy input? • Harvesting – how, costs (< 500 ppm, <50 micron cells)• Cultivation – selected strains, grazers, weed algae, etc.• Processing – how dry, make biogas (oil extraction later)

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U.C. Berkeley, Richmond Field Station,Sanitary Engineering Research Lab. ca 1976

1st use paddle-wheels for mixing large ponds (and of “bioflocculation” harvesting)

Microactinium

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Raceway paddle wheel mixed high rate open ponds now the main (>99%) commercial production systems for microalgae

Spirulina

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Solix Biofuel Pilot Plant, 2010, in ColoradoHanging bags in pool, note many valves, connections, etc.Solix Biofuel Pilot Plant, 2010, in Colorado

Hanging bags in pool, note many valves, connections, etc.

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Commercial Photobioreactor in Germany

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Algatech Commerical Photobioreactors, Israel (>250 km tubes) for Haematococcus (Astaxanthin)

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Cyanotech Co.Open, raceway ponds, algae plant in Hawaii. Red ponds for Haematococcus pluvialis for astaxanthin, others Spirulina

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Basic Schematic of Algae Biofuels Production with open ponds: alternative inputs, products, scenariosBasic Schematic of Algae Biofuels Production

with open ponds: alternative inputs, products, scenarios

Lundquist, T., I. Woertz, N. Quinn and J. Benemann, 2010 “A Realistic Technology and Engineering Assessment of Algae Biofuel Production”, Energy Biosciences Inst., U.C. Berkeley

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NEXT TOPIC: CO2 - Many companies around world using PBRs to capturing CO2 E.on- Hamburg, Germany

NEXT TOPIC: CO2 - Many companies around world using PBRs to capturing CO2 E.on- Hamburg, Germany

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RWE, Germany, hanging bags PBR to capture CO2from a coal-fired power plant.

RWE, Germany, hanging bags PBR to capture CO2from a coal-fired power plant.

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Biodiesel Power Plant with CO2 Scrubber, 320 kW output can provide all the CO2 needed

and most (~80%) of power needed

Biodiesel Power Plant with CO2 Scrubber, 320 kW output can provide all the CO2 needed

and most (~80%) of power needed

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CO2 transfer sump at Roswell New Mexico Pilot Plant (Weissman et al., 1990, Aquatic Species Program,

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Ponds, Christchurch NZ 5 hectares, 4 ponds Largest algae for biofuels project in world. Investigator: Dr. Rupert Craggs at NIWA

LOWEST COST BIOFUELS PRODUCTION SYSTEM

Sump for CO2 transfer

Paddle wheel

Lamellar settler harvesting

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Algal wastewater treatment with “high rate” pondsAlgal wastewater treatment with “high rate” ponds

Use “high-rate ponds”(raceway, paddle wheel mixed) for wastewater treatment, nutrient (N, P)reclamation, production of biofuels, greenhouse gas abatement

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Resource Limitations to Microalgae limit the global potential of microalgae biomass

Resource Limitations to Microalgae limit the global potential of microalgae biomass

• Water – Saline (near sea), Fresh (food competition), brackish (?)

• Nutrients - 5-10% N, 0.3-1% P, very high! must recycle efficiently

• Carbon – CO2 from fossil power plants - sustainable? available?

• Land – Must be nearly flat, clay-type soil (liners are expensive!)

• Climate – “Goldilocks” (not too cold, not too hot, just right).

Water-Nutrients-Carbon-Land-Climate NEED ALL AT SAME SITE!

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THE POTENTIAL AND PROMISE OF MICROALGAEcurrent US food/fuel crops vs. future algae production

THE POTENTIAL AND PROMISE OF MICROALGAEcurrent US food/fuel crops vs. future algae productionU.S. Avg. Yield Protein/oil 1,000s Ha Protein – oil(equiv.)

CROP Mt/ha-yr Mt/ha-yr Harvested million Mt/yr - bbl/yrCORN GRAIN 7.0 0.77/starch 30,000 23,000 440,000* SOYBEAN 1.5 0.9/0.30 30,000 27,000 60,000ALGAE for feed 100 50/10 1,000 50,000 ---

for fuel 100 30/40 1,000 30,000 250,000 NOTE: crop productivities are actual, algae are future projections CONCLUSION: 1 million ha of algae farms could replace US proteinfeed production (~ 10% of world) or ~1% of world liquid fuels use). Assumes 40% actual oil yield (2.5 bbl/mt, 40,000 l/ha-yr) from algae •All figures rounded/approx.: U.S. avg. corn yield avg. 8.2 mt/ha-yr adjusted for 15% moisture and yield of 0.5 l EtOH/kg dry corn x 0.67 for oil eq. and 160 l/bblAverage soy yield and content of protein 60%, oil 20% (2 bbl/ha biodiesel yield).

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Sapphire Energy, New MexicoAurora Biofuels, Florida Sapphire Energy,planned, New Mexico

Examples of microalgaebiofuels projects 2010 Eni, 1 ha pilot plant, Gela,

Sicily, Italy, operating Algenol, planned Florida (bag PBR)

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THANK YOU!

ANY QUESTIONS?

32Algal Biomass Organization | www.algalbiomass.org

• Not-for-profit organization with more than 170 members globally (>60 corporate members)

• Membership comprises, individuals, companies and research organizations across value chain

• Promotes development of viable technologies and commercial markets for renewable and sustainable products derived from algae

• Hosts and produces meetings, seminars and global events: Algae Biomass Summit 5, Minneapolis October 25-27, CALL FOR PAPERS

• Advocates on behalf of industry to local, state and federal governments

Algal Biomass Organization Algal Biomass Organization