Synthetic and biologically-derived products produced using biomass produced by photobioreactors configured for mitigation of pollutants in flue gases

• US 20050239182A1
• Filed: 04/14/2005
• Published: 10/27/2005
• Est. Priority Date: 05/13/2002
• Status: Abandoned Application

• Current Assignee: GreenFuel Technologies Corporatio
• Original Assignee: IHI INC. (IHI Corporation)
• Inventors: Berzin, Isaac
• Application Number:
  US11/106,695
• Publication Number:
  US 20050239182A1
• Time in Patent Office: Days
• US Class Current: 435/166
• CPC Class Codes: C12M 21/02 Photobioreactors culturing algae A01G33/00, A01H4/001, C12N1/12
• CPC Class Codes: C12M 43/02 Bioreactors or fermenters combined with devices for liquid fuel extraction; Biorefineries
• CPC Class Codes: C12M 43/04 Bioreactors or fermenters combined with combustion devices or plants, e.g. for carbon dioxide removal C12M43/06 takes precedence; recovery of carbon dioxide C12F3/02
• CPC Class Codes: C12M 43/06 Photobioreactors combined with devices or plants for gas production different from a bioreactor of fermenter
• CPC Class Codes: C12M 43/08 Bioreactors or fermenters combined with devices or plants for production of electricity
• CPC Class Codes: C12P 7/56 Lactic acid

Abstract

Certain embodiments and aspects of the present invention relate to photobioreactor apparatus designed to contain a liquid medium comprising at least one species of photosynthetic organisms therein, and to methods of using the photobioreactor apparatus as part of a production process for forming an organic molecule-containing product, such as a polymeric material and/or fuel-grade oil (e.g. biodiesel), from biomass produced in the photobioreactor apparatus. In certain embodiments, the disclosed organic molecule/polymer production systems and methods, photobioreactor apparatus, methods of using such apparatus, and/or gas treatment systems and methods provided herein can be utilized as part of an integrated combustion and polymer and/or fuel-grade oil (e.g. biodiesel) production method and system, wherein photosynthetic organisms utilized within the photobioreactor are used to at least partially remove certain pollutant compounds contained within combustion gases, e.g. CO₂ and/or NO_x, and are subsequently harvested from the photobioreactor, processed, and utilized as a source for generating polymers and/or organic molecule-containing products (e.g. fuel-grade oil (e.g. biodiesel)) and/or as a fuel source for a combustion device (e.g. an electric power plant generator and/or incinerator).

Claims

1. A method comprising acts of:

providing a liquid medium comprising at least one species of photosynthetic organism within an enclosed photobioreactor;

exposing at least a portion of the photobioreactor and the at least one species of photosynthetic organisms to sunlight, thereby driving photosynthesis;

harvesting at least a portion of the photosynthetic organisms from the bioreactor to form biomass; and

converting at least a portion of the biomass into a product comprising at least one organic molecule.

2. A method as in claim 1, wherein the product comprising at least one organic molecule comprises a polymer.

3. A method as in claim 1, wherein the product comprising at least one organic molecule comprises a fuel-grade oil.

4. A method as in claim 3, wherein the fuel-grade oil comprises biodiesel.

5. A method as in claim 1, wherein the converting act further comprises isolating a polymer from the biomass.

6. A method as in claim 5, wherein the polymer comprises a polysaccharide.

7. A method as in claim 6, wherein the polysaccharide comprises starch.

8. A method as in claim 7, wherein the converting step further comprises reacting the starch to form the product comprising the at least one organic molecule.

9. A method as in claim 1, wherein the converting act further comprises using the biomass and/or one or more components generated and/or isolated therefrom as a source of at least one nutrient in a fermentation.

10. A method as in claim 9, wherein the converting act further comprises synthesizing the product comprising at least one organic molecule from a substance produced by the fermentation.

11. A method as in claim 10, wherein the substance produced by the fermentation comprises lactic acid, lactate salts, lactate esters or mixtures thereof.

12. A method as in claim 10, wherein the product comprises at least one organic molecule comprising a polymer.

13. A method as in claim 12, wherein the polymer is biodegradable and/or bioerodable.

14. A method as in claim 12, wherein the polymer comprises an aliphatic polyester.

15. A method as in claim 14, wherein the polymer comprises a homopolymer or copolymer of lactic acid or lactide.

16. A method as in claim 15, wherein the polymer comprises poly(lactic acid) or polylactide homopolymer.

17. A method as in claim 1, comprising establishing a flow of the liquid medium comprising at least one species of photosynthetic organisms within the photobioreactor.

18. A method as in claim 17, further comprising acts of:

calculating a first exposure interval of the photosynthetic organisms to the light at an intensity sufficient to drive photosynthesis and a second exposure interval of the photosynthetic organisms to dark or the light at an intensity insufficient to drive photosynthesis required to yield a selected growth rate of the photosynthetic organisms within the photobioreactor; and

controlling the flow of the liquid medium within the photobioreactor based on the exposure intervals determined in the calculating step.

19. A method as in claim 17, further comprising acts of:

performing a simulation of liquid flow patterns within the photobioreactor and, from the simulation, determining a first exposure interval of the photosynthetic organisms to light at an intensity sufficient to drive photosynthesis and a second exposure interval of the photosynthetic organisms to dark or light at an intensity insufficient to drive photosynthesis;

calculating from the first exposure interval and the second exposure interval a predicted growth rate of the photosynthetic organisms within the photobioreactor; and

controlling the flow of the liquid medium within the photobioreactor so as to yield a selected first exposure interval and a selected second exposure interval of the photosynthetic organisms to achieve a desired predicted growth rate as determined in the calculating step.

20. A method as in claim 1, further comprising an act of:

introducing a stream of gas to be treated to the photobioreactor; and

at least partially removing from the gas with the photobioreactor CO₂ and/or NO_x.

21. A method as in claim 20, wherein the gas introduced in the introducing step comprises combustion gas derived from a power generating apparatus and/or an incinerator.

22. A method as in claim 19, wherein predicted growth rate calculated in the calculating step from the first and second exposure intervals is determined utilizing a mathematical model that simulates the growth rate of the photosynthetic organisms when exposed to alternating periods of exposure to light at an intensity sufficient to drive photosynthesis and exposure to light at an intensity insufficient to drive photosynthesis.

23. A method as in claim 17, wherein the establishing step comprises:

introducing a first stream of a gas to be treated by the photobioreactor to a first gas sparger configured and positioned to introduce the gas stream into a first conduit of the photobioreactor;

introducing a second stream of the gas to be treated by the photobioreactor to a second gas sparger configured and positioned to introduce the gas stream into a second conduit of the photobioreactor;

inducing the liquid medium to flow in the first conduit in a direction that is counter-current to a direction of flow of gas bubbles formed from the first stream of gas introduced into the first conduit; and

inducing the liquid medium to flow in the second conduit in a direction that is co-current to a direction of a flow of gas bubbles formed from the second stream of gas introduced into the second conduit.

24. A method as in claim 1, wherein the at least one species of photosynthetic organisms within the photobioreactor comprises algae.

25. A method comprising an act of:

facilitating at least one of the production of a polymer and the conversion of biomass into a product comprising at least one organic molecule by providing biomass that is formed from at least one species of photosynthetic organisms, and that was produced in an enclosed photobioreactor utilizing the sun as a source of light for driving photosynthesis by the at least one species of photosynthetic organisms during biomass production in the photobioreactor.

26. A method as in claim 25, wherein the product comprising at least one organic molecule comprises a fuel-grade oil.

27. A method as in claim 25, wherein the fuel-grade oil comprises biodiesel.

28. A method as in claim 25, wherein the photobioreactor is supplied with a feed gas comprising CO2 and/or NOx, at least one of which is at least partially removed from the feed gas by the at least one species of photosynthetic organisms during biomass production in the photobioreactor.

29. A method as in claim 25, wherein the at least one species of photosynthetic organisms comprises algae and the biomass comprises algal biomass.

30. A method as in claim 29, further comprising an act of:

producing the biomass provided in the providing act.

31. A method as in claim 25, wherein the feed gas comprises combustion gas derived from a power generating apparatus and/or incinerator.

32. A method as in claim 25, further comprising an act of:

providing instructions for generating and/or directions to generate the polymer and/or other product comprising at least one organic molecule from the biomass.

33. An integrated combustion and biomass-derived organic molecule containing product production method comprising acts of:

burning a fuel with a combustion device to produce a combustion gas stream;

passing the combustion gas to an inlet of an enclosed photobioreactor containing a liquid medium therein comprising at least one species of photosynthetic organisms and exposed to the sun as a source of light driving photosynthesis within the photobioreactor;

at least partially removing at least one substance from the combustion gas with the photosynthetic organisms, the at least one substance being utilized by the organisms for growth and reproduction;

removing at least a portion of the at least one species of photosynthetic organisms from the photobioreactor to form a biomass product; and

transforming at least a portion of the biomass into a product comprising at least one organic molecule.

34. A method as in claim 33, wherein the transforming act comprises converting at least a portion of the biomass into the product comprising at least one organic molecule.

35. A method as in claim 33, wherein the transforming act comprises isolating from at least a portion of the biomass the product comprising at least one organic molecule.

36. A method as in claim 33, wherein the product comprising at least one organic molecule comprises a polymer.

37. A method as in claim 33, wherein the product comprising at least one organic molecule comprises a fuel-grade oil.

38. A method as in claim 37, wherein the fuel-grade oil comprises biodiesel.

39. An integrated combustion and polymer production method as in claim 33, wherein the at least one species of photosynthetic organisms comprises algae and wherein the dried biomass product comprises a dried algal biomass product.

40. A method comprising acts of:

providing a liquid medium comprising at least one species of photosynthetic organisms within an array of a plurality of photobioreactors;

exposing at least a portion of the photobioreactors and the at least one species of photosynthetic organisms to a source of light capable of driving photosynthesis;

harvesting at least a portion of the photosynthetic organisms from the bioreactors to form biomass; and

converting at least a portion of the biomass into a product comprising at least one organic molecule.

41. An integrated combustion and biomass-derived organic molecule containing product production method comprising acts of:

burning a fuel with a combustion device to produce a combustion gas stream;

passing the combustion gas to an inlet of an array of a plurality of photobioreactors containing a liquid medium therein comprising at least one species of photosynthetic organisms and exposed to a source of light capable of driving photosynthesis within the photobioreactors;

at least partially removing at least one substance from the combustion gas with the photosynthetic organisms, the at least one substance being utilized by the organisms for growth and reproduction;

removing at least a portion of the at least one species of photosynthetic organisms from the photobioreactors to form a biomass product; and

transforming at least a portion of the biomass into a product comprising at least one organic molecule.