Closed system bioreactor apparatus

• US 20070048859A1
• Filed: 08/24/2006
• Published: 03/01/2007
• Est. Priority Date: 08/25/2005
• Status: Abandoned Application

• Current Assignee: Solix Biofuels, Inc.
• Original Assignee: Sunsource Industries Incorporated
• Inventors: Sears, James
• Application Number:
  US11/510,442
• Publication Number:
  US 20070048859A1
• Time in Patent Office: Days
• US Class Current: 435/289.100
• CPC Class Codes: C10G 2300/1011 Biomass
• CPC Class Codes: C12M 21/02 Photobioreactors culturing algae A01G33/00, A01H4/001, C12N1/12
• CPC Class Codes: C12M 21/12 for producing fuels or solvents C12M21/04 takes precedence; liquid carbonaceous fuels C10L1/00, solid fuels C10L5/00
• CPC Class Codes: C12M 23/06 Tubular C12M23/08, C12M23/16 take precedence
• CPC Class Codes: C12M 23/20 Material Coatings immunocoatings C12M25/00
• CPC Class Codes: C12M 23/26 flexible flexible containers for laboratory use B01L3/505
• CPC Class Codes: C12M 29/22 Oxygen discharge
• CPC Class Codes: C12M 33/10 by centrifugation centrifuges in general B04B; Cyclones cyclones in general B04C
• CPC Class Codes: C12M 33/18 Rollers
• CPC Class Codes: C12M 37/00 Means for sterilizing, maintaining sterile conditions or avoiding chemical or biological contamination C12M23/38 takes precedence; filtration in general and filters per se B01D24/00-B01D41/00; autoclaves B01J3/04; treatment of microorganisms with electrical or wave energy C12N13/00
• CPC Class Codes: C12M 41/24 inside the vessel
• 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: C12N 1/12 Unicellular algae; Culture media therefor as new plants A01H13/00
• CPC Class Codes: C12P 1/00 Preparation of compounds or compositions, not provided for in groups C12P3/00 - C12P39/00, by using microorganisms or enzymes
• CPC Class Codes: C12P 5/00 Preparation of hydrocarbons or halogenated hydrocarbons
• CPC Class Codes: C12P 7/649 Biodiesel, i.e. fatty acid alkyl esters
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02E 50/30 Fuel from waste, e.g. synthetic alcohol or diesel
• CPC Class Codes: Y02P 30/20 using bio-feedstock

Abstract

The present disclosure concerns an apparatus and system comprising closed bioreactors for aquaculture and harvesting. In certain embodiments, the system may comprise bags with various layers, including a thermal barrier layer, that may be used to contain the aquaculture and/or to thermally regulate the temperature of the aquaculture. The system may comprise various mechanisms for moving fluid within the system, such as a roller type mechanism, and may provide temperature regulation by compartmentalization of the fluid to regulate absorption of solar radiation and/or conductive or emissive heat loss and gain. Various mechanisms may be used to harvest aquatic organisms grown in the apparatus and process them into commercially useful products, such as biodiesel, methane, animal or human food, substrates for polymer synthesis or other chemical products.

Claims

1. A closed system bioreactor apparatus comprising:

a) one or more flexible tubes capable of containing an aqueous medium;

b) one or more peristaltic rollers operably coupled to the tubes to circulate the medium through the tubes and to remove gas bubbles from the tubes; and

c) a thermal barrier within the one or more tubes to regulate the temperature of the medium, wherein the medium may be alternatively directed above or below the barrier to thermally isolate or thermally expose the medium to the environment.

2. The apparatus of claim 1, further comprising multiple axial vortex inducers vertically arranged within the tubes to provide rotation of the aqueous medium within the tubes.

3. The apparatus of claim 2, wherein adjacent axial vortex inducers are arranged with opposite clockwise and counterclockwise twists.

4. The apparatus of claim 1, wherein the tubes are arranged horizontally along the ground.

5. The apparatus of claim 1, further comprising two flexible tubes and two peristaltic rollers, each tube operably coupled to a single peristaltic roller.

6. The apparatus of claim 5, further comprising a first and second control housing operably coupled to the ends of the two tubes to form a biologically closed system.

7. The apparatus of claim 1, further comprising one or more aquatic organisms in the medium.

8. The apparatus of claim 7, further comprising a whirlpool device in the first control housing to concentrate the organisms.

9. The apparatus of claim 8, further comprising one or more sipper tubes operably coupled to the whirlpool device to remove concentrated organisms from the apparatus.

10. The apparatus of claim 7, further comprising a gas bubbler in the second control housing to provide CO₂ to the aqueous medium.

11. The apparatus of claim 5, wherein the movement of the peristaltic rollers along the tubes removes oxygen or other gases from the medium.

12. The apparatus of claim 7, wherein the movement of the peristaltic rollers along the tubes cleans the upper and lower surfaces of the tubes and resuspends organisms that have settled to the bottom of the tube.

13. The apparatus of claim 4, wherein the height of the thermal barrier above the ground may be adjusted to control the temperature of the aqueous medium.

14. The apparatus of claim 13, wherein during daylight hours the flow of the aqueous medium is directed below the thermal barrier to maintain the temperature of the suspension at ground temperature or above the thermal barrier to warm the suspension.

15. The apparatus of claim 13, wherein during nighttime hours the flow of the aqueous medium is directed above the thermal barrier to cool the suspension and below the thermal barrier to maintain the temperature of the medium at ground temperature.

16. The apparatus of claim 1, wherein the outer surface of the tubes is comprised of 0.01 inch thick polyethylene.

17. The apparatus of claim 1, wherein the thermal barrier is comprised of 1.0 inch thick polyethylene foam.

18. The apparatus of claim 1, wherein the upper surface of the thermal barrier comprises a layer of sand, a translucent ceramic or plastic, a silicate or glass.

19. The apparatus of claim 18, wherein the upper surface of the thermal barrier exhibits an infrared emissivity of close to 1.0.

20. The apparatus of claim 7, wherein the upper surface of the tubes is indented with a linear Frenel pattern that collects sunlight from a lower Snell'"'"'s law angle and directs it into the aquatic organisms in the medium.

21. The apparatus of claim 20, where the tubes are layed out perpendicular to the low angle southern sun for the winter months in temperate climates.

31. A system for producing biodiesel from algae comprising:

a) a closed bioreactor apparatus according to claim 1, the bioreactor containing a suspension of algae in aqueous medium;

b) a mechanism for harvesting the algae from the medium;

c) a device for separating oil from the algae; and

d) an apparatus for converting the oil into biodiesel.

32. The system of claim 31, wherein the mechanism for harvesting algae comprises a whirlpool device and one or more sipper tubes.

33. The system of claim 31, wherein the device for separating oil from the algae comprises at least one centrifuge.

34. The system of claim 31, wherein the apparatus for converting oil into biodiesel utilizes a transesterification process.

22. A closed system bioreactor apparatus comprising:

a) two flexible tubes capable of containing an aqueous medium;

b) two peristaltic rollers operably coupled to the tubes to circulate the medium through the tubes;

c) multiple axial vortex inducers vertically arranged within the tubes to provide rotational exposure of the aqueous medium to sunlight; and

d) a first and a second control housing operably coupled to the ends of the tubes to form a biologically closed system.

23. The apparatus of claim 22, further comprising a thermal barrier within the one or more tubes to regulate the temperature of the medium, wherein the medium may be alternatively directed above or below the barrier to expose or isolate the medium from its thermal environment.

24. The apparatus of claim 23, further comprising a mechanism within the first control housing to direct the medium above or below the barrier.

25. The apparatus of claim 24, wherein the mechanism comprises at least one stiff septum linked to at least one actuator that positions the septum to direct the medium above or below the barrier.

26. The apparatus of claim 22, further comprising a whirlpool device in the first control housing to form a vortex in the medium.

27. The apparatus of claim 26, further comprising one or more sipper tubes operably coupled to the whirlpool device.

28. The apparatus of claim 22, further comprising a gas bubbler in the second control housing to provide CO₂ to the aqueous medium.

29. The apparatus of claim 28, wherein the gas bubbler comprises a perforated neoprene membrane through which gas is bubbled.

30. The apparatus of claim 29, wherein gas bubbles are introduced at the bottom of a water column, the water moving in a downward direction and the gas bubbles moving in an upward direction.