Integrated photobioreactor-based pollution mitigation and oil extraction processes and systems

• US 20080009055A1
• Filed: 01/22/2007
• Published: 01/10/2008
• Est. Priority Date: 07/10/2006
• Status: Abandoned Application

• Current Assignee: GreenFuel Technologies Corporatio
• Original Assignee: GreenFuel Technologies Corporatio
• Inventors: Lewnard, John J.
• Application Number:
  US11/656,330
• Publication Number:
  US 20080009055A1
• Time in Patent Office: Days
• US Class Current: 435/262
• CPC Class Codes: B01D 2257/404 Nitrogen oxides other than dinitrogen oxide
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: B01D 53/84 Biological processes
• CPC Class Codes: C10G 1/002 in combination with oil conversion- or refining processes
• CPC Class Codes: C12M 21/02 Photobioreactors culturing algae A01G33/00, A01H4/001, C12N1/12
• CPC Class Codes: C12M 23/56 Floating elements
• CPC Class Codes: Y02A 50/20 Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02C 20/40 of CO2
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02P 20/59 Biological synthesis; Biological purification
• CPC Class Codes: Y02W 10/37 using solar energy

Abstract

Integrated systems including a photobioreactor system designed to contain a liquid medium comprising at least one species of phototrophic organism therein, and a facility associated with extracting and/or processing oil extracted from mixtures of oil and solid material, such as an oil sands facility, are described. Processes for using a photobioreactor system as part of a gas-treatment process and system able to at least partially remove certain undesirable pollutants from a byproduct gas stream produced by an oil sands facility are also described. Examples of such pollutants that may be removed include compounds contained within combustion gases, e.g., CO₂ and/or NO_x. These pollutants processed with the photobioreactor system, and, in some embodiments, biomass produced with the photobioreactor system may be utilized to produce a fuel source (e.g., biodiesel) and cutting stock for further operation of or use in the oil sands facility. Such uses of certain embodiments can provide an efficient means for recycling carbon, thereby reducing CO₂ emissions, fuel, and/or cutting stock requirements for a given quantum of energy produced. In addition, in some cases the photobioreactor can be integrated with a holding pond and waste heat from the oil extraction process can be used to maintain the photobioreactor temperature and/or provide energy for other processes. Accordingly, embodiments described herein can improve the overall environmental and economic profile of the oil sands facility.

Claims

1. An integrated oil processing and gas remediation method comprising acts of:

processing an oil extracted from a mixture of an oil and a solid material excavated from the earth to produce a processed oil product, wherein a byproduct gas stream is produced during the processing act;

passing at least a portion of the byproduct gas stream into an inlet of a photobioreactor system containing a liquid medium therein comprising at least one species of phototrophic organisms; and

at least partially removing at least one substance from the byproduct gas stream with the phototrophic organisms, the at least one substance being utilized by the organisms for growth and reproduction.

2. A method of claim 1, further comprising before the processing act, an act of extracting the oil from the mixture of an oil and a solid material excavated from the earth.

3. A method of claim 1, further comprising an act of removing at least a portion of the at least one species of phototrophic organisms from the photobioreactor system to form a biomass product.

4. A method of claim 3, further comprising an act of using at least a portion of the biomass product to produce liquid fuel product.

5. A method of claim 4, further comprising an act of using at least a portion of the liquid fuel product as cutting stock.

6. A method of claim 3, further comprising an act of using at least a portion of the biomass product and/or a fuel product derived from the biomass as fuel for a furnace and/or electrical power generating system.

7. A method of claim 1, wherein CO₂ is removed from the byproduct gas stream during the at least partially removing act.

8. A method of claim 1, wherein NO_x is removed from the byproduct gas stream during the at least partially removing act.

9. An integrated oil production and gas treatment system comprising:

an oil extraction and processing facility configured to extract oil from a mixture of an oil and a solid material excavated from the earth and to process extracted oil to produce a processed oil product, wherein the facility comprises at least one gas outlet from which is emitted a byproduct gas stream; and

a photobioreactor system containing a liquid medium comprising at least one species of phototrophic organisms, at least a portion of the photobioreactor system being configured to transmit light to the phototrophic organisms, the photobioreactor system comprising an inlet connected in fluid communication with at least one gas outlet of the facility, the photobioreactor system further comprising an outlet configured to release treated gas from the photobioreactor system.

10. A system of claim 9, wherein the oil extraction and processing facility further comprises a heat and/or power generating system configured to provide heat and/or power to facilitate at least one of oil extraction and processing of extracted oil, wherein the heat and/or power generating system comprises at least one gas outlet from which is emitted a byproduct gas stream, and wherein at least one gas outlet of the heat and/or power generating system is connected in fluid communication with the inlet of the photobioreactor system.

11. A system of claim 9, wherein the oil extraction and processing facility is an oil sands extraction and processing facility.

12. A method of claim 11, wherein the oil sands extraction and processing facility is a surface mining facility.

13. A method of claim 9, wherein the mixture comprises bitumen.

14. A method of claim 9, wherein the photobioreactor is constructed and arranged to float on a holding pond associated with the oil extraction and processing facility.

15. A method of claim 14, wherein at least one source of waste heat produced by the facility is in heat transfer communication with the pond so as to utilize the pond as a waste heat sink, thereby heating the water in the pond.

16. A method of claim 9, wherein the oil extraction and processing facility comprises a catalytic reforming and/or water-gas-shift reactor.

17. A method of claim 9, wherein the oil extraction and processing facility comprises a catalytic oil hydrogenation reactor.

18. A method of claim 9, wherein the oil extraction and processing facility comprises a coking reactor.

19. A method of claim 9, wherein the photobioreactor system comprises a plurality of interconnectable photobioreactor sections which, when connected together, form at least one longitudinally-oriented photobioreactor unit of the photobioreactor system, the photobioreactor sections each comprising a liquid flow channel and a light-transparent cover that forms a gas headspace between the cover and the liquid flow channel;

wherein the cover is constructed and arranged to cover at least a substantial portion of the liquid flow channel and is configured to be capable of providing the gas headspace even when a gas pressure within the photobioreactor unit is less than the atmospheric pressure surrounding the photobioreactor section.

20. A method of claim 9, wherein the photobioreactor system comprises at least one photobioreactor section constructed and arranged to carry a flow of liquid medium comprising phototrophic organisms therein;

the photobioreactor section comprising;

a cover constructed and arranged to cover at least a substantial portion of the liquid medium within the photobioreactor section and further constructed and arranged to provide a gas headspace under the cover and above the liquid medium, the cover being capable of providing the gas headspace even when a gas pressure within the photobioreactor is less than the atmospheric pressure surrounding the photobioreactor section;

a liquid inlet to provide liquid medium to the photobioreactor section;

a liquid outlet from which to remove liquid medium comprising phototrophic organisms therein from the photobioreactor section;

a gas inlet to provide gas containing an elevated concentration of carbon dioxide into the gas headspace;

a gas outlet from which to remove gas containing carbon dioxide at a concentration less than at the gas inlet; and

a blower fluidically connected to the gas outlet able to create a flow of gas through the gas headspace from the gas inlet to the gas outlet.

21. A method of claim 9, wherein the photobioreactor system comprises at least one longitudinally extending photobioreactor unit comprising at least one photobioreactor section, the photobioreactor unit being constructed and arranged to carry a flow of liquid medium comprising phototrophic organisms therein;

the photobioreactor unit comprising;

at least one cover constructed and arranged to cover at least a substantial portion of the liquid medium within the photobioreactor unit and constructed and arranged to provide a gas headspace under the cover and above the liquid medium, the cover being capable of providing the gas headspace even when a gas pressure within the gas headspace of the photobioreactor is less than the atmospheric pressure surrounding the photobioreactor unit;

a first liquid inlet constructed and arranged to provide a liquid medium to the photobioreactor unit;

a first liquid outlet from which the liquid medium is removable from the photobioreactor unit;

a second liquid outlet positioned between the first liquid inlet and the first liquid outlet, from which the liquid medium is removable from the photobioreactor unit; and

a channel fluidically interconnecting the second liquid outlet to the photobioreactor unit at a position which is upstream of the second liquid outlet to enable return and recycle of the liquid medium within the photobioreactor unit.

22. A method of claim 9, wherein the photobioreactor system comprises at least one photobioreactor section constructed and arranged to carry a flow of liquid medium comprising phototrophic organisms therein;

the photobioreactor section comprising;

a cover constructed and arranged to cover at least a substantial portion of the liquid medium within the photobioreactor section and constructed and arranged to provide a gas headspace under the cover and above the liquid medium, the gas headspace being maintainable at a pressure that differs from atmospheric pressure;

a liquid inlet configured to provide liquid medium to the photobioreactor section;

a liquid outlet from which liquid medium is removable from the photobioreactor section; and

a gas outlet from which gas containing carbon dioxide at a concentration less than at the gas inlet is removable from the photobioreactor section;

wherein

the photobioreactor section comprises a first portion of the photobioreactor section in which the cover provides the gas headspace over a first portion of the liquid medium, and further comprises a second, different portion of the photobioreactor section in which a second portion of the liquid medium is exposed to gas outside of the gas headspace to facilitate evaporative cooling of the liquid medium.

23. A method of claim 9, wherein the photobioreactor system comprises at least one photobioreactor section constructed and arranged to carry a flow of liquid medium comprising phototrophic organisms therein and a flow of gas containing an elevated concentration of carbon dioxide;

the photobioreactor section comprising;

a liquid inlet constructed and arranged to provide at least liquid medium to the photobioreactor section;

a liquid outlet from which liquid medium is removable from the photobioreactor section;

a gas inlet constructed and arranged to provide gas containing an elevated concentration of carbon dioxide to the photobioreactor section;

a gas outlet from which gas containing carbon dioxide at a concentration less than at the gas inlet is removable from the photobioreactor section;

a cover constructed and arranged to cover at least a substantial portion of the flow of liquid medium within the photobioreactor section and constructed and arranged to provide a gas headspace under the cover and above the liquid medium;

wherein the photobioreactor section includes a portion of the photobioreactor section where the liquid medium is exposed to gas outside of the gas headspace to facilitate evaporative cooling of the liquid medium, and

wherein the photobioreactor system comprises a controller configured to control the amount of evaporative cooling of the liquid medium in the portion of the photobioreactor section where the liquid medium is exposed to gas outside of the gas headspace.

24. A method of producing biomass comprising acts of:

providing a liquid medium comprising at least one species of phototrophic organisms within a photobioreactor system;

exposing at least a portion of the photobioreactor system and the at least one species of phototrophic organisms to a source of light capable of driving photosynthesis;

introducing a byproduct gas stream derived at least in part from an oil extraction and processing facility configured to extract oil from a mixture of an oil and a solid material excavated from the earth and to process extracted oil to produce a processed oil product, and/or introducing a byproduct gas stream derived from a furnace and/or electrical power generating system associated with the oil extraction and processing facility, to an inlet of the photobioreactor system; and

harvesting at least a portion of the phototrophic organisms from the photobioreactor system to form biomass.

25. A method of claim 24, further comprising an act of generating a liquid fuel product from the biomass.

26. A method of claim 24, wherein the oil extraction and processing facility comprises an oil sands facility.

27. A method of claim 26, wherein the oil sands facility is a surface mining facility.

28. A method of claim 24, wherein the mixture comprises bitumen.

29. A method of claim 24, wherein the photobioreactor is constructed and arranged to float on a holding pond associated with the oil extraction and processing facility.

30. A method of claim 24, wherein heat from the holding pond is used to maintain a temperature within the photobioreactor.

31. A method of claim 24, further comprising drying the biomass.

32. A method of claim 24, wherein the byproduct gas stream comprises CO₂ and/or NO_x.

33. A method of claim 24, wherein the byproduct gas stream is produced during processing of oil extracted from a mixture of an oil and a solid material excavated from the earth.

34. A method of claim 33, wherein the byproduct gas stream comprises a reaction product emitted from a catalytic reforming and/or water-gas-shift reactor of a system used to process the oil extracted from a mixture of an oil and a solid material excavated from the earth to produce the processed oil product.

35. A method of claim 34, wherein the system used to process the oil extracted from a mixture of an oil and a solid material excavated from the earth to produce the processed oil product further comprises a catalytic oil hydrogenation reactor.

36. A method of claim 24, wherein the byproduct gas stream comprises combustion gas produced by a furnace and/or electrical power generating system.

37. A method of claim 36, wherein the furnace and/or electrical power generating system is used to provide thermal energy to a coking reactor used to process the oil extracted from a mixture of an oil and a solid material excavated from the earth to produce the processed oil product.

38. A method of claim 24, comprising at least partially removing CO₂ and/or NO, from the byproduct gas stream with the photobioreactor.

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

40. A method as in claim 24, wherein the source of light capable of driving photosynthesis comprises the sun.

41. A method as in claim 25, further comprising an act of blending at least a portion of the liquid fuel product derived from the biomass with at least a portion of the processed oil product produced from the oil extraction and processing facility.

42. A method as in claim 24, further comprising an act of using at least a portion of the liquid fuel product derived from the biomass as fuel for the furnace and/or electrical power generating system.