System and Method for Producing Algae

• US 20130244310A1
• Filed: 10/09/2012
• Published: 09/19/2013
• Est. Priority Date: 03/19/2012
• Status: Active Grant

• Current Assignee: Algae To Omega Holdings, Inc.
• Original Assignee: Geronimos Dimitrelos
• Inventors: Dimitrelos, Geronimos
• Granted Patent: US 9,243,219 B2
• Time in Patent Office: Days
• US Class Current: 435/257.3
• CPC Class Codes: C12M 21/02 Photobioreactors culturing algae A01G33/00, A01H4/001, C12N1/12
• CPC Class Codes: C12M 23/06 Tubular C12M23/08, C12M23/16 take precedence
• CPC Class Codes: C12M 23/22 Transparent or translucent parts glassware for laboratory use B01L3/00
• CPC Class Codes: C12M 23/58 Reaction vessels connected in series or in parallel combinations of bioreactors with other apparatus, C12M43/00
• CPC Class Codes: C12M 27/04 with introduction of gas through the stirrer or mixing element
• CPC Class Codes: C12M 31/02 located outside the reactor
• CPC Class Codes: C12M 31/08 by conducting or reflecting elements located inside the reactor or in its structure
• CPC Class Codes: C12M 31/10 by light emitting elements located inside the reactor, e.g. LED or OLED
• CPC Class Codes: C12M 41/24 inside the vessel
• CPC Class Codes: C12N 1/12 Unicellular algae; Culture media therefor as new plants A01H13/00
• CPC Class Codes: C12N 11/04 entrapped within the carrier, e.g. gel or hollow fibres

Abstract

A system and method of growing and harvesting algae provided whereby the system encompasses incubation tanks, internal lighting, chilled air diffusers, and an inline incubation tank for continuous batch processing. A centrifuge separates algae from growth media, and the media is processed through a series of reclamation steps so that cleaned water is reused for fresh media.

Claims

1. A system for producing algae comprising:

an algae production tank having algae growth media therein;

a light located inside the production tank, the light capable of being submerged in the growth media;

a rotating blade proximate a bottom of the production tank for the purpose of mixing the growth media.

2. The system for producing algae of claim 1 further comprising a substantially transparent cylinder that houses the light source.

3. The system for producing algae of claim 1 wherein the light is an LED.

4. The system for producing algae of claim 3 wherein the LED produces light in the spectrum from about 420 nm to about 720 nm.

5. The system for producing algae of claim 3 wherein the LED produces light in the ultraviolet spectrum.

6. The system for producing algae of claim 1 further comprising a tubular skylight connected to the production tank to divert sunlight into the production tank.

7. The system for producing algae of claim 1 wherein the light is fiber optic lighting that transmits sunlight to the interior of the production tank.

8. A system for producing algae of claim 1, wherein the algae is at least one of Haematococcus pluvialis, Chlorella zofingiensis, and Scenedesmus species.

9. The system for producing algae of claim 1 further comprising an air chiller that passes cooled air through the production tank for the purpose of cooling and aerating the growth media.

10. The system for producing algae of claim 9 further comprising a diffuser attached to the blade, the diffuser connected to the chiller so that cooled air introduced into the diffuser is released from the diffuser into the production tank to form a rotating curtain of air upon blade rotation.

11. The system for producing algae of claim 9 wherein the cooled air is passed through the cylinder for the purpose of cooling the cylinder and light source.

12. The system for producing algae of claim 9 wherein a sheath substantially surrounding the production tank defining a space between the sheath and the production tank wherein cooled air exhausted from the production tank and into the space for externally cooling the production tank.

13. The system for producing algae of claim 1 further comprising an incubation tank attached proximate a top of the production tank, the incubation tank defining an opening whereby contents of the incubation tank can pass therethrough to the production tank.

14. The system for producing algae of claim 13 further comprising a junction between the incubation tank and the production tank that is sealed to prevent contaminants from entering the incubation tank and the production tank.

15. The system for producing algae of claim 1, wherein water used for the growth media is reclaimed water.

16. The system for producing algae of claim 1 further comprising a water reclamation system comprising a particulate filter to filter particulate matter from used growth media, a UV light source to kill living organisms, a reverse osmosis membrane, and gaseous ozone, wherein used growth media is cleaned and resulting cleaned water is utilized as a component of new growth media.

17. The system for producing algae of claim 1 further comprising a centrifuge connected to the production tank, wherein the algae in the growth media is introduced into the centrifuge to substantially separate the algae from the growth media.

18. The system for producing algae of claim 1 further comprising a plurality of beads in the growth media to limit algae growth on interior surfaces of the system.

19. The system for producing algae of claim 18 wherein the beads comprise sodium alginate.

20. The system for producing algae of claim 18 wherein the beads comprise a pH buffering agent.

21. The system for producing algae of claim 18 wherein the beads comprise algal cells.

22. A system for producing algae comprising:

an algae production tank having algae growth media therein;

a visible light source located inside the production tank, the light capable of being submerged in the growth media;

a rotating blade proximate a bottom portion of the production tank for the purpose of mixing the growth media;

a diffuser inside the production tank proximate the bottom portion;

an air chiller that introduces chilled and filtered air through the diffuser and into the growth media to chill and aerate the media; and

an incubation tank for producing culture attached proximate a top of the production tank, the incubation tank defining an opening whereby contents of the incubation tank can pass therethrough to the production tank.

23. The system for producing algae of claim 22 further comprising a particulate filter to filter particulate matter from used growth media, a UV light source to kill living organisms, a reverse osmosis membrane, and gaseous ozone, wherein used growth media is cleaned.

24. A method for producing algae comprising the steps of:

incubating a first algae culture in a volume of growth media within an incubation tank;

transferring the first algae culture to a production tank having a greater capacity than the incubation tank;

adding additional media to the production tank to increase the volume of media therein;

increasing a cell density of the first culture in the production tank;

incubating a second algae culture in a growth media within the incubation tank;

transferring the second algae culture to the production tank;

diffusing cooled air into the production tank; and

providing a light source inside the production tank.

25. The method for producing algae of claim 24 further comprising the steps of:

incubating a third algae culture in a growth media within the incubation tank; and

transferring the third algae culture to the production tank.

26. The method for producing algae of claim 24 further comprising the steps of:

exhausting the cooled air from the production tank; and

directing the cooled air proximate the incubation tank.

27. The method for producing algae of claim 24 further comprising the steps of:

exhausting the cooled air from the production tank; and

directing the cooled air proximate an exterior surface of the production tank.

28. The method for producing algae of claim 24 further comprising the steps of:

transferring the media from the production tank to a centrifuge; and

centrifuging the media to separate algae growing in the media from the media.

29. The method for producing algae of claim 28 further comprising the step of reclaiming water from centrifuged media for use in fresh media.

30. The method for producing algae of claim 24 further comprising the step of placing beads in the growth media.

31. The system for producing algae of claim 30 wherein the beads comprise sodium alginate.

32. The system for producing algae of claim 30 wherein the beads comprise a pH buffering agent.

33. The system for producing algae of claim 30 wherein the beads comprise algal cells.