Algae bioreactor using submerged enclosures with semi-permeable membranes

• US 8,409,845 B2
• Filed: 12/05/2008
• Issued: 04/02/2013
• Est. Priority Date: 12/05/2008
• Status: Active Grant

• Current Assignee: SETI Institute, USA As Represented By The Administrator Of The NASA
• Original Assignee: The United States of America As Represented By The Secretary of Agriculture
• Inventors: Baertsch, Robert, Gormly, Sherwin J, Buckwalter, Patrick W, Delzeit, Lance D, Trent, Jonathan D, Flynn, Michael T, Embaye, Tsegereda N, Liggett, Travis A
• Primary Examiner(s): Beisner, William H
• Application Number:
  US12/316,557
• Publication Number:
  US 20100216203A1
• Time in Patent Office: 1,579 Days
• Field of Search: 435/257.1, 435/292.1, 47/14
• US Class Current: 435/257.1
• CPC Class Codes: A01G 33/00 Cultivation of seaweed or algae
• CPC Class Codes: C12M 21/02 Photobioreactors culturing algae A01G33/00, A01H4/001, C12N1/12
• CPC Class Codes: C12M 23/14 Bags
• CPC Class Codes: C12M 23/26 flexible flexible containers for laboratory use B01L3/505
• CPC Class Codes: C12M 23/56 Floating elements
• CPC Class Codes: C12M 47/02 Separating microorganisms from the culture medium; Concentration of biomass separating microorganisms from their culture media C12N1/02
• CPC Class Codes: Y02A 40/80 in fisheries management
• CPC Class Codes: Y02P 60/20 Reduction of greenhouse gas [GHG] emissions in agriculture, e.g. CO2

Abstract

Methods for producing hydrocarbons, including oil, by processing algae and/or other micro-organisms in an aquatic environment. Flexible bags (e.g., plastic) with CO₂/O₂ exchange membranes, suspended at a controllable depth in a first liquid (e.g., seawater), receive a second liquid (e.g., liquid effluent from a “dead zone”) containing seeds for algae growth. The algae are cultivated and harvested in the bags, after most of the second liquid is removed by forward osmosis through liquid exchange membranes. The algae are removed and processed, and the bags are cleaned and reused.

Claims

1. A method for producing at least one micro-organism (“

μ

org”

), the method comprising;

providing a closeable enclosure, having an enclosure interior and being defined by first and second opposed enclosure surfaces that are joined together;

partially or fully immersing the enclosure in a first type liquid;

partially filling the enclosure with the at least one μ

org and a second type liquid;

closing the enclosure with the second type liquid and the at least one μ

org contained in the enclosure interior, where at least one of the enclosure first and second surfaces comprises one or more semi-permeable first membranes that are permeable to the second type liquid and are substantially impermeable to the at least one μ

org;

allowing at least a portion of the second type liquid within the enclosure interior to pass through the one or more first membranes into the first type liquid by forward osmosis, to thereby remove at least a portion of the second type liquid in the enclosure interior;

providing at least one of the enclosure first surface and the enclosure second surface with at least one CO₂ transport membrane having a CO₂ transport rate across the transport membrane that can be changed; and

increasing or decreasing the rate of CO₂ transport across the transport membrane into said enclosure, in order to bring a present CO₂ concentration value, C(CO₂), into closer agreement with a selected CO₂ concentration value, C(CO₂;

ref).

2. The method of claim 1, further comprising removing said at least one μ

org from said enclosure interior when said at least one μ

org has reached at least a selected μ

org growth stage.

3. The method of claim 1, further comprising:

providing said at least one or more semi-permeable first membranes on said enclosure first surface; and

submerging said enclosure first surface in order to promote transport of said second type liquid through said one or more first membranes into said first type liquid.

4. The method of claim 1, further comprising choosing said first type liquid/second type liquid to have a non-zero gradient of a selected chemical across at least one of said one or more first membranes.

5. The method of claim 4, further comprising choosing a combination of said first type liquid/second type liquid to be at least one of marine water/non-marine water, brine/marine water, and brine/non-marine water.

6. The method of claim 4, further comprising choosing said second type liquid to comprise effluent water.

7. The method of claim 1, further comprising initially positioning said enclosure so that a portion of said enclosure second surface is initially submerged in said first type liquid to influence passage of said second type liquid through at least one of said one or more of said first membranes.

8. The method of claim 1, further comprising providing de-eutrophication of a portion of said first type liquid adjacent to said enclosure first surface by passage of said portion of said second type liquid through said one or more first membranes into said first type liquid.

9. The method of claim 1, further comprising increasing salinity of said second type liquid within said enclosure.

10. The method of claim 1, further comprising selecting at least one of said one or more first membranes from a group of semi-permeable membranes that contain small pores and are hydrophobic.

11. The method of claim 1, further comprising choosing said one or more first membranes to have a thickness in a range 1-20 mils.

12. The method of claim 1, further comprising choosing said at least one μ

org to be an alga that produces at least one lipid.

13. The method of claim 12, further comprising choosing said at least one lipid-producing alga to include at least one animal feed compound.

14. The method of claim 12, further comprising choosing said at least one lipid-producing alga to include at least one fertilizer component.

15. The method of claim 12, wherein said at least one lipid-producing compound produces a compound drawn from a group of hydrocarbons consisting of fuel oil, diesel fuel, aviation fuel, gasoline, kerosene, alkanes, alkenes, alkynes, alcohols, ethers, aldehydes, ketones, esters, amines, amides, benzene ring-based hydrocarbons and cyclic hydrocarbons.

16. The method of claim 1, further comprising removing a portion of said second type liquid and said at least one μ

org from said enclosure interior at first and second selected times that are spaced apart from each other.

17. The method of claim 16, further comprising choosing a difference between said second selected time and said first selected time to be no greater than about ten days.

18. The method of claim 1, further comprising removing, from said enclosure, and processing said at least one μ

org, to produce at least one lipid with a lipid weight of at least 20 percent dry weight of said at least one μ

org, and to serve as an inocculum for subsequent growth of said μ

org.

19. The method of claim 1, further comprising submerging said enclosure in said first type liquid to a continuously variable or discretely variable, selected depth h so that said enclosure is substantially completely submerged below a surface of said first type liquid.

20. The method of claim 19, wherein said process of submerging said enclosure in said body of said first type liquid to said selected depth h comprises:

providing at least two inflatable submersion enclosures, attached to said enclosure to be submerged, with each submersion enclosure having a selected weight attached thereto and being partly filled with a selected fluid that has a lower density than said first type liquid and a lower density than said second type liquid, where the sum of the weights attached to a submersion enclosure is selected so that (i) when all of the selected fluid is withdrawn from all the submersion enclosures, the enclosure to be submerged will sink toward a bottom of said first type liquid and (ii) when sufficient fluid is admitted into the plurality of submersion enclosures, the enclosure to be submerged will float on said surface of said first type liquid,

whereby said depth of said enclosure is continuously or discretely varied by withdrawing the selected fluid from, or adding the selected fluid to, at least one submersion enclosure.

21. The method of claim 19, wherein said process of submerging said enclosure to be submerged in said body of said first type liquid to said selected depth h comprises:

providing one or more float modules that are capable of floating on or near said liquid surface;

providing one or more tethers, each tether having a first end attached to at least one float module and having a second end attached to or associated with said enclosure;

providing a tether roll-up/reel-out mechanism, located adjacent to the first end or adjacent to the second end of each of the one or more tethers, that decreases a length d of the associated tether or increases the length d of the associated tether, upon receipt of a roll-up command signal or a reel-out command signal, respectively; and

providing a roll-up/reel-out command control mechanism, connected to each of the at least two tether roll-up/reel-out mechanisms, to provide a roll-up command signal or, alternatively, a reel-out command signal to the tether roll-up/reel-out mechanism,

whereby said depth h of said enclosure is continuously varied or discretely varied by varying the length d of the associated tether.

22. The method of claim 19, further comprising controllably submerging said enclosure first surface to a depth in a range of 0-20 meters below said first type liquid surface.

23. The method of claim 19, further comprising providing at least one of said enclosure first surface and said enclosure second surface with at least one hollow core rib that can be inflated by introduction of a selected fluid into the at least one hollow core rib.

24. The method of claim 1, further comprising:

providing N enclosures (N≧

2), produced according to claim 3; and

attaching each of the N enclosures to at least one of the other N−

1 enclosures so that the N enclosures form a connected structure that can be moved in said body of first type liquid from a first location to a second location that is spaced apart from the first location.

25. The method of claim 1, further comprising:

partially or fully immersing said enclosure in said first type liquid; and

allowing heat capacity of said first type liquid to subsequently maintain a temperature of said second type liquid approximately equal to a temperature of said first type liquid.

26. The method of claim 1, further comprising allowing wave action in said first type liquid to thereby promote mixing of contents of said second type liquid within said enclosure.

27. The method of claim 1, further comprising providing said second type liquid within said enclosure with an average depth having a range within said enclosure of 5-20 cm.

28. The method of claim 1, further comprising allowing light that is incident on said enclosure, to illuminate said at least one μ

org and to promote growth of said at least one μ

org within said enclosure.

29. The method of claim 28, further comprising providing said enclosure second surface with an enclosure interior surface that receives and reflects substantially all light incident thereon within a selected wavelength range.

30. The method of claim 1, further comprising providing said enclosure first surface with an enclosure substance that receives incident light and transmits the incident light into said second type liquid only if at least one wavelength of the incident light is within a selected wavelength range.

31. The method of claim 1, wherein said at least one CO₂ transport membrane includes a plurality of mesh screen apertures that provide gas bubbles containing CO₂ gas having gas bubble diameters less than a selected threshold diameter, within said enclosure interior, to thereby promote absorption of said CO₂ gas bubbles within said second type liquid.

32. The method of claim 1, further comprising:

providing at least one second membrane that permits transport of O₂ from said enclosure interior to an exterior of said enclosure.

33. The method of claim 1, further comprising:

providing a controller that controls said present CO₂ concentration value C(CO₂) within said second type liquid relative to said selected CO₂ concentration value, C(CO₂;

ref).

34. A method for producing at least one micro-organism (“

μ

org”

), the method comprising;

providing a first type liquid;

providing a sealable enclosure, having an enclosure interior and being defined by first and second enclosure surfaces;

partially filling the enclosure interior with a second type liquid, and providing at least one selected micro-organism (“

μ

org”

) in the enclosure interior;

closing the enclosure;

positioning the enclosure in the first type liquid;

providing at least one of the first and second enclosure surfaces with one or more semi-permeable first membranes that are permeable to at least one of CO₂ gas and NH₃ gas and are substantially impermeable to the at least one selected μ

org;

providing an exterior source of at least one of CO₂ gas and NH₃ gas in contact with the one or more first membranes;

providing a controller that senses a pH value, pH(sens), within the second type liquid, compares the value pH(sens) with a reference value, pH(ref), for the pH value within the second type liquid, and introduces at least one of the CO₂ gas and the NH₃ gas into the second type liquid in order to bring pH(sens) into closer agreement with pH(ref);

providing a semi-permeable second membrane, positioned on at least one of the first and second enclosure surfaces, that is permeable to the second liquid and is not permeable to the at least one μ

org; and

allowing at least a portion of the second type liquid within the enclosure interior to pass through the second membrane, positioned on at least one of the first and second enclosure surfaces, into the first type liquid by forward osmosis, to thereby remove at least part of the second type liquid from the enclosure interior.

35. The method of claim 34, further comprising choosing said pH reference value in a range 3.5≦

pH(ref)≦

9.5.

36. A method for producing at least one micro-organism (“

μ

org”

), the method comprising;

providing a sealable enclosure, having an enclosure interior and being defined by first and second opposed enclosure surfaces that are joined together;

partially or fully immersing the enclosure in a first type liquid;

partially filling the enclosure with the at least one μ

org and a second type liquid;

closing the enclosure with the second type liquid and the at least one μ

org contained in the enclosure interior, where at least one of the enclosure first and second surfaces comprises one or more semi-permeable first membranes that are permeable to the second type liquid and are substantially impermeable to the at least one μ

org;

allowing at least a portion of the second type liquid within the enclosure interior to pass through the one or more first membranes into the first type liquid by forward osmosis, to thereby remove at least a portion of the second type liquid in the enclosure interior;

providing the one or more first membranes on the enclosure first surface; and

positioning at least one of the one or more first membranes above a surface of the first type liquid in order to reduce or suppress transport of said second liquid through the first membrane into said first type liquid.

37. A method for producing at least one micro-organism (“

μ

org”

), the method comprising;

providing a sealable enclosure, having an enclosure interior and being defined by first and second opposed enclosure surfaces that are joined together;

partially or fully immersing the enclosure in a first type liquid;

partially filling the enclosure with the at least one μ

org and a second type liquid;

closing the enclosure with the second type liquid and the at least one μ

org contained in the enclosure interior, where at least one of the enclosure first and second surfaces comprises one or more semi-permeable first membranes that are permeable to the second type liquid and are substantially impermeable to the at least one μ

org;

allowing at least a portion of the second type liquid within the enclosure interior to pass through the one or more first membranes into the first type liquid by forward osmosis, to thereby remove at least a portion of the second type liquid in the enclosure interior; and

providing one or more second membranes on at least one of the first enclosure surface and the second enclosure surface, which are permeable to at least one selected nutrient for the at least one μ

org.

38. A method for producing at least one micro-organism (“

μ

org”

), the method comprising;

providing a sealable enclosure, having an enclosure interior and being defined by first and second opposed enclosure surfaces that are joined together;

partially or fully immersing the enclosure in a first type liquid;

partially filling the enclosure with the at least one μ

org and a second type liquid;

closing the enclosure with the second type liquid and the at least one μ

org contained in the enclosure interior, where at least one of the enclosure first and second surfaces comprises one or more semi-permeable first membranes that are permeable to the second type liquid and are substantially impermeable to the at least one μ

org;

allowing at least a portion of the second type liquid within the enclosure interior to pass through the one or more first membranes into the first type liquid by forward osmosis, to thereby remove at least a portion of the second type liquid in the enclosure interior; and

adding a selected chemical to the second type liquid to promote production of at least one of CO₂ and NH₃ within the enclosure.

39. A method for producing at least one micro-organism (“

μ

org”

), the method comprising;

providing a sealable enclosure, having an enclosure interior and being defined by first and second opposed enclosure surfaces that are joined together;

partially or fully immersing the enclosure in a first type liquid;

partially filling the enclosure with the at least one μ

org and a second type liquid;

closing the enclosure with the second type liquid and the at least one μ

org contained in the enclosure interior, where at least one of the enclosure first and second surfaces comprises one or more semi-permeable first membranes that are permeable to the second type liquid and are substantially impermeable to the at least one μ

org;

allowing at least a portion of the second type liquid within the enclosure interior to pass through the one or more first membranes into the first type liquid by forward osmosis, to thereby remove at least a portion of the second type liquid in the enclosure interior; and

applying a process of inverting positions of said enclosure first surface and said enclosure second surface, relative to a surface of said first liquid, to reduce or terminate forward osmosis that has begun across the one or more first membranes.