Solar biofactory, photobioreactors, passive thermal regulation systems and methods for producing products

• US 8,304,209 B2
• Filed: 12/11/2009
• Issued: 11/06/2012
• Est. Priority Date: 12/11/2008
• Status: Expired due to Fees

• Current Assignee: Joule Unlimited Technologies, Inc.
• Original Assignee: Joule Unlimited Technologies, Inc.
• Inventors: van Walsem, Johan, Morgan, Frederick, Jacobson, Stuart A., Ponzel, Rainer, Michonski, Scott A., Posner, Andrew, McIntire, James R.
• Primary Examiner(s): Ariani, Kade
• Application Number:
  US13/061,116
• Publication Number:
  US 20110151507A1
• Time in Patent Office: 1,061 Days
• Field of Search: None
• US Class Current: 435/41
• 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 23/04 Flat or tray type, drawers C12M23/10, C12M23/12, C12M23/16 take precedence
• CPC Class Codes: C12M 41/20 the heat transfer medium being a gas
• CPC Class Codes: C12N 1/12 Unicellular algae; Culture media therefor as new plants A01H13/00
• CPC Class Codes: C12N 1/20 Bacteria; Culture media therefor
• CPC Class Codes: C12N 13/00 Treatment of microorganisms or enzymes with electrical or wave energy, e.g. magnetism, sonic waves
• CPC Class Codes: C12P 5/02 acyclic C12P5/007 takes precedence
• CPC Class Codes: C12P 7/02 containing a hydroxy group
• CPC Class Codes: C12P 7/065 with microorganisms other than yeasts
• CPC Class Codes: C12P 7/16 Butanols
• CPC Class Codes: C12P 7/40 containing a carboxyl group including Peroxycarboxylic acids
• CPC Class Codes: C12P 7/649 Biodiesel, i.e. fatty acid alkyl esters
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel

Abstract

The invention described herein relates to photobioreactors, methods, assembly and use of such apparatus for culturing light-capturing organisms in a cost-effective manner. Various embodiments provide for a passive thermal regulation system employing selected microorganisms in a photobioreactor apparatus and methods for biological production of various fuel and chemical products from these organisms. Additional embodiments provide a solar biofactory system capable of culturing light capturing organisms to an areal productivity of 3.3 g/m2/hr. Further embodiments are directed to a photobioreactor capable of culturing light capturing organisms to an OD₇₃₀ of about 14 g/L DCW. Such embodiments incorporate passive thermal regulation and systems.

Claims

1. A method for producing fuels or chemicals comprising:

(a) employing a photobioreactor assembly comprising;

a reactor structure; and

a greenhouse structure configured to provide a greenhouse environment for the reactor structure, the reactor structure and the greenhouse structure spaced relative to each other to provide temperature control of the photobioreactor, wherein the reactor structure comprises a closed reactor and the greenhouse structure comprises at least two side sheets spaced apart with the reactor disposed therebetween;

(b) introducing into the reactor of the photobioreactor assembly at least one phototroph;

(c) culturing the phototroph in the reactor of the photobioreactor assembly whereby the phototroph utilizes light and CO₂ to produce the fuels or chemicals.

2. The method of claim 1, further comprising employing an assembly comprising a real time adaptive control system to maintain optimum productivity.

3. The method of claim 1, wherein the passive thermal regulation system regulates temperature of the photobioreactor between about 25°

C. to about 60°

C.

4. The method of claim 1, wherein the photobioreactor separates the fuels or chemicals continuously.

5. The method of claim 1, wherein the reactor contains a biomass concentration of less than 20 g/L, 10 g/l or 5 g/L.

6. The method of claim 1, wherein the phototroph is an engineered phototroph, the method further comprising culturing the engineered phototroph to an OD₇₃₀ of about 14 g/L dry cell weight.

7. The method of claim 1, wherein the phototroph is an engineered phototroph, the method further comprising culturing the engineered phototroph to an optical cell density of at least 2-5 g/L, 5-10 g/L or 10-20 g/L dry cell weight.

8. The method of claim 1, further comprising removing the fuels or chemicals from the photobioreactor.

9. The method of claim 1, wherein the photobioreactor is adapted to achieve passive thermal control of the enclosed reactor within about 5°

C. to about 10°

C. of ambient air temperature.

10. The method of claim 1, wherein the phototroph is an engineered phototroph, and the engineered phototroph utilizes light and CO₂ to produce the fuels or chemicals at an areal productivity of at least about 0.4 g/m²/hr.