http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

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the algae experiment: How to build your own algae photo-bioreactor.by m0uch on January 15, 2012

Table of Contents

the algae experiment: How to build your own algae photo-bioreactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intro:   The algae experiment: How to build your own algae photo-bioreactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 1:   Shape, size & materiality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 2:   The ribs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 3:   The Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 4:   How it came together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Step 5:   The plinth/base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Step 6:   Colour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Step 7:   Sealing the bio-reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Step 8:   Hose fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Step 9:   Test Runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Step 10:   Growing the Initial algae culture pt I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Step 11:   Growing the Initial algae culture pt II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Step 12:   Test runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Step 13:   Outcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

Intro:  The algae experiment: How to build your own algae photo-bioreactor.In this instructable we will go over how to construct an at-home version of a photo-bioreactor which will use solar energy and artificial lighting with carbon dioxide toproduce algae biomass.

The aim of this project is to create an model which harbors an ecosystem fit to help us escape a fossil fuel economy. We are in an era that is experiencing a shift fromhumanity trying to dominate nature, to then trying to preserve parts of nature and now trying to reach a reconciliation with nature. This is the algae experiment; an ideathat is trying to move away from a linear wasteful and polluting way of using resources to a closed loop system where all resources are kept in a closed loop cycle.

Follow the possibilities of harvesting algae for fuel & see the difficulties met along this journey on-line at

@@@: thealgaeexperiment.tumblr.com

a published paper on the subject can be found on

@@@: http://issuu.com/mouchmouch/docs/thealgaeexperiment

Step 1: Shape, size & materialityThe over all shape of the photo bioreactor is inspired from a previous project I had been working on where it follows a mean summer solar path of the UK. It is meant tobe both an educational model but also embody certain architectural elements within allowing it to possibly be viewed as an informational pavilion.

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

Step 2: The ribsI considered using two materials for the support system.

I tried clear acrylic so as not detract from the function, which would be the algae tubes containing the algae. However. having to deal with all the transparencies of thematerials made the model seem very confusing.

I needed each rib to consist of two pieces of wood in order to provide a stable ‘leg’ for each segment whilst I would be putting the model together but also to be able towithstand any rocking from pressure the model would experience during the cultivation hours. I ordered 50 M4 grub screws with a cup point and 150 M4 hexagon nutsand got started on the ribs. (M4 denotes the diameter of the screw; 4mm) I spaced the ribs apart 20mm which allowed them to be able to free stand. Together all 5 setsmade a very sturdy model base.

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

Step 3: The TubesI wanted to use a closed loop system where the algae would travel constantly and safely without getting contaminated, so using clear acrylic tubes was the best option.

I initially wanted to use 15mm outer diameter tubes with an inner diameter of 12mm in order to carry the water required to grow the algae, as well as to match the pumppower (4000 Liters per hour) that I had obtained for a previous model. However I quickly realized that at every return point of each tube there was no silicone or plasticbased hose that was flexible enough to bend around to each connection point.

This wasn’t all disappointing as it meant that I could downsize to 12mm outer diameter tubes with an inner diameter of 8mm and save on cost at the same time.Unfortunately even though I moved down to that size, finding a hose which would fit on the outside of the 12mm seemed impossible.

That is when I decided to try to enter the 8mm inner area of the tube; something considered very unconventional and ‘inconvenient’ but to me this was the only optionas far as flexibility was concerned with the materials available to me. I found a 8mm outer diameter silicone tube and it fit perfectly inside.

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

Step 4: How it came togetherThe trouble now was to sort out the frequency and amount of tubes per rib. I needed enough to cover as much of the surface as possible in order for the algae to captureas much light as possible. I therefore ordered 20 x 1m length 12mm outer diameter tubes. This allowed me enough spacing to double up in the future on the inside if Icould raise more money to have a second set under the first set of ribs.

Although at first one pair of tubes seemed easy to connect to each other with the 8mm silicone hose, repeating the process 40 times with such a small radius and atendency to buckle in and fold on itself seemed impractical. I therefore had to come up with a different system of transporting the algae from one tube to the next. Thismeant either re-designing the ribs to a much larger scale which would set each tube further apart or changing the tube to an even smaller size which would allow me topurchase an even thinner hose with more flexibility to achieve that goal.

I decided not to go with either, instead I changed the pattern of transport; rather than consecutively going from tube to tube, I would skip 3 tubes on one end and 2 on theother, 3 on one, 2 on the other and so on and so forth. This allowed me to stick with the same design & tubes which were already put together and get a much largerradius which would ensure that the hoses would not pop out of place because of the pressure or their internal positioning in the acrylic tubes

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

Step 5: The plinth/baseWith the ‘above ground’ part of the model completed, it was now time for the plinth to be constructed which would house all the mechanisms that would operate themodel ‘below ground’. The plinth required to place the model on a height which would be comfortable to be viewed by an audience of both children & the elderly but atthe same time not be overstated and detract from the model itself.

I decided to make it 1m tall and allow 15cm for each side of the 1m tubes to have space for the turnaround of the hoses. The final dimensions of the plinth were 1m tall,1,3m long by 0.3m wide.

As this was going to be both an exhibition piece and a University project I felt that there was a strong educational aspect to it. I wanted to somehow be able to tell thestory of the algae with this model. I decided to make viewing holes on the rear side which would show the process much like the doughnut company Krispy Kreme hascertain stores where the customers can see the production line of how the doughnuts are made from the dough to the glazing.

On these holes I would label what each component would do. Bio-reactor, CO2 pump, air intake, light source. Once deciding on the location of these objects, I decidedthat rather than having separate holes with separate names, it would be better to have one panel which would be seen as one object containing all the information oneneeds to know which would be far less distracting.

This turned out to be a really good choice after all and the laser cutting machine did an excellent job. Etching turned out to be much harder than I thought as every letterhad to be converted to an object which meant that there was a much higher chance for an error to occur. Each letter had to be checked and cleared of any unwantedlines as well as check for disconnections in the comprising lines.

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

Step 6: ColourAfter that the plinth was ready for painting, a clean white look turned out to be the right choice and a color scheme of white, natural ply & clear proved successful. Inhindsight I should have used far less paint quantity on the water tank door as the 3mm ply could not handle the paint and warped. It is purely an aesthetic problem, onethat can be addressed after the exhibition is over.

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

Step 7: Sealing the bio-reactorWith the plinth drying it was now time to seal the tubes and the hoses shut to make a closed loop bio-reactor. I used the super-instant glue rather than silicone because ofits ‘instant factor’ and the fact that the hose & tube were such a tight fit that silicone would only create clumps inside the tube and probably cause more problems than itwas worth.

When trying to fit each hose in the tubes it was extremely hard to get each one in at first. To solve the problem I countersunk all the tubes in order to get a ‘start’ in eachhose so that it could slide in with ease. This was an excellent solution as later I poured glue on the countersunk tube with the hose in place which created a lake whichwould seal shut. Result: not a single connection out of the 40 connections leaked.

Because the tube was a very small space with a limited air supply, the instant glue would not dry instantly, this created a small puddle inside each connection. I thereforehad to try various positions every 5~7 minutes to ensure that each connection would seal on all 360o.

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

Step 8: Hose fittingA minor adjustment had to be made to the pumping mechanism. Due to the fact that the 4000 Liters per hour was significantly more powerful than the 15 Liter water tankI was intending to use I had to make an outlet where the pumps power would effectively be cut in half in order to take the stress off all the plumbing connections so theywould not suddenly blow apart from the pressure.

The adjustable handle also meant that I could regulate the speed at which the algae would travel round the model and effectively either accelerate or decelerate thegrowth when needed.

Whilst I would be transporting the model, I would like to have the ability to separate the bio-reactor from the plynth. I used some heavy duty clip-on clip-off fittings whichallowed me to completely disconnect the bio-reactor without compromising any connection points.

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

Step 9: Test RunsAfter letting the glue settle for 40 hours, the first test run with still water was extremely successful. The air bubbles traveled at a steady pace throughout the model and allthe connections held up perfectly. This run lasted for 4 hours. I then proceeded to add algae incrementally over the next week.

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

Step 10: Growing the Initial algae culture pt IDuring the building period, I had started to grow algae using the simple method of a water bottle, algae food & the sun. This proved successful in the UK but even moresuccessful in Greece where the sun lasted for longer during the day. I started with a culture sent to me by the Algae Depot of 50ml and after a few days I reached 3 x100ml travel bottles.

I then proceeded to continue to grow that culture until I eventually reached the required 5.5 Liters after approximately 2 weeks. The algae was growing exponentiallyquicker due to the limited bottle room I would provide along with excellent sun exposure and feeding regime.

Step 11: Growing the Initial algae culture pt II

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

Step 12: Test runsI let the algae run in the bio-reactor for 10 days and achieved excellent results.Perhaps it was the location of the model posistioned against a window which received very good sunlight both artificial and genuine but it had grown at a steady pacebecoming greener every day.

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

Step 13: OutcomeBeing an ongoing project I do not have the algae biomass output of this experiment yet.

I will keep you posted through my tumblr blog

http://thealgaeexperiment.tumblr.com/

where any publications results and other events that will be organised shall be posted.

Thank you for looking through this instructable and please contact me if you need any further info.

Charles

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

Related Instructables

Simple AlgaeHome CO2Scrubber - PartII AlgaeCultures andBreeding byegbertfitzwilly

Photo-Bioreactor forAlgae &AquacultureUsing RecycledBottles byharmane

AnAlgaeBioreactor fromRecycled WaterBottles bymfischer

Simple AlgaeHome CO2Scrubber - Part1 byegbertfitzwilly

PopbottleAlgae! byOrangeBacon

How To Make anAlgae TestPhotoBioreactor...PartFive by dsieg58

Comments

3 comments Add Comment

 golddigger1559 says:  Jan 15, 2012. 9:11 AM  REPLYwhat application can this be applied to? i mean, why would i want to build something like this?

 m0uch says:  Jan 15, 2012. 12:19 PM  REPLYHiggs is right, through processing the biomass you can get a new form of fuel essentially.

If you would like to read more I have published a paper on the whole project on issuu.

http://issuu.com/mouchmouch/docs/thealgaeexperiment

http://www.instructables.com/id/the-algae-experiment-How-to-build-your-own-algae-/

 Higgs Boson says:  Jan 15, 2012. 11:21 AM  REPLYwell for one thing algae produces natural gas that can be used instead of fossil fuels.