Enclosed bioreactor system and methods associated therewith

• US 8,569,050 B1
• Filed: 05/03/2010
• Issued: 10/29/2013
• Est. Priority Date: 05/04/2009
• Status: Active Grant

• Current Assignee: Eric Burt, Georgine, Jane A. Barnes
• Original Assignee: John D. Ericsson
• Inventors: Ericsson, John D.
• Primary Examiner(s): Beisner, William H
• Application Number:
  US12/772,970
• Time in Patent Office: 1,275 Days
• Field of Search: 435/292.1, 435/294.1, 435/295.1, 435/295.2, 435/296.1, 422/227, 422/605
• US Class Current: 435/292.1
• CPC Class Codes: C12M 21/02 Photobioreactors culturing algae A01G33/00, A01H4/001, C12N1/12
• CPC Class Codes: C12M 21/08 for producing artificial tissue or for ex-vivo cultivation of tissue prostheses A61F2/00, grafts A61L27/00
• CPC Class Codes: C12M 27/24 Draft tube C12M29/08 takes precedence
• CPC Class Codes: C12M 31/02 located outside the reactor
• CPC Class Codes: C12M 31/10 by light emitting elements located inside the reactor, e.g. LED or OLED
• CPC Class Codes: C12N 1/12 Unicellular algae; Culture media therefor as new plants A01H13/00

Abstract

A bioreactor production system for growing commercial volumes of algae or other biomass in a uniquely configured, enclosed, biosecure, photo-type reactor vessel, having internal artificial growth light production as well as exterior solar energy capturing devices or the like designed to facilitate enhanced sunlight exposure for photosynthesis organism production. A unique electromagnetic field generation system is integrated with the bioreactor and its operation to substantially enhance growth rate and overall productivity.

Claims

1. A bioreactor, comprising:

a containment vessel having a wall having inner and outer sides forming an interior having an inner diameter, lower and upper ends, and a medial area therebetween;

a generally vertically oriented flow tube concentrically situated in said interior of said containment vessel, said flow tube forming a longitudinal passage having a bottom, a top, and a medial area therebetween;

said flow tube having laterally formed therethrough, in the vicinity of said medial area of said longitudinal passage, a medial flow aperture;

a sliding gate valve comprising a buoyant, cylindrical body formed to slidingly engage said wall of said flow tube so as to selectively block flow through said medial flow aperture upon said interior of said containment vessel being filled to a predetermined fluid level.

2. The bioreactor of claim 1, wherein there is further provided an auxiliary flat panel bioreactor in fluid communication with said containment vessel, said auxiliary flat panel bioreactor having a top side and an underside comprising:

first and second panels mounted in a spaced fashion to define an enclosure therebetween, said first panel formed of light permeable material, said enclosure having a length and first and second ends, said first panel defining said top side of said auxiliary flat panel bioreactor, said second panel defining said underside of said auxiliary flat panel bioreactor;

a first tube having a length, said first tube formed to disperse into said enclosure flowing matter, said first tube situated in the vicinity of said first end of said enclosure;

wherein said auxiliary flat panel bioreactor is situated exterior to said containment vessel, said enclosure is formed to receive a flow of liquid biomass suspension from said containment vessel via said first tube, and said auxiliary flat panel bioreactor is formed to facilitate the passage of said flow of liquid biomass suspension through said enclosure so as to receive light energy radiating therein.

3. The bioreactor of claim 2, wherein said auxiliary flat panel bioreactor further comprises a diffuser situated adjacent and linearly aligned with said first tube, said diffuser being formed to receive and diffuse gas therefrom so as to urge biomass and fluid in said liquid biomass suspension, provide turbulence in said enclosure to enhance exposure of biomass in said liquid biomass suspension to said light energy as it flows through said enclosure, and facilitate the flow of said liquid biomass suspension from said enclosure to said containment vessel.

4. The bioreactor of claim 3, wherein said second panel of said auxiliary flat panel bioreactor is formed of a light permeable material, and wherein there is further provided an artificial light source mounted to project light through said second panel into said enclosure, so as to radiate light energy into said enclosure.

5. The bioreactor of claim 2, wherein said first and second panels of said bioreactor comprise a layer of one-way reflective material formed to prevent light from passing out of said enclosure, said one-way reflective material formed to allow the one-way passage of light through said first and second panels into said enclosure, respectively, so as to form a reflective light chamber between said first and second panels, so as to better expose said light to any flowing matter passing therethrough.

6. The bioreactor system of claim 2, wherein there is further provided a diaphragm pump formed to provide a surging flow of liquid biomass suspension from said containment vessel to said auxiliary flat panel bioreactor, and through said first tube of said auxiliary flat panel bioreactor, so as to provide enhanced flow through said enclosure and back to said containment vessel.

7. The bioreactor of claim 1, wherein said cylindrical body of said sliding gate valve has formed therethrough a flow passage.

8. The bioreactor of claim 7, wherein said flow tube has mounted thereto a lower stop situated below said medial flow aperture, and wherein said lower stop is positioned to support said cylindrical body of said sliding gate valve such that said flow passage of said cylindrical body is aligned with said medial flow aperture of said flow tube, so as to allow the flow of matter therethrough.

9. The bioreactor of claim 8, wherein said flow tube has mounted thereto an upper stop situated above said medial flow aperture, wherein said upper stop is positioned to stop upward migration of said cylindrical body of said sliding gate valve due to buoyancy, such that said cylindrical body of said sliding gate valve blocks said medial flow aperture formed in said flow tube, to substantially prevent the passage of fluid therethrough.

10. The bioreactor of claim 1, wherein said flow tube has mounted thereto an upper stop situated above said medial flow aperture, wherein said upper stop is positioned to stop upward migration of said cylindrical body of said sliding gate valve due to buoyancy, so as to position said cylindrical body of said sliding gate valve to block said medial flow aperture formed in said flow tube, so as to substantially prevent the passage of fluid therethrough.

11. The bioreactor of claim 10, wherein there is provided a lower airlift in said flow tube below said medial area of said flow tube, said lower airlift formed to provide a pressure gradient to provide lift in said flow tube.

12. The bioreactor of claim 11, wherein there is provided an upper airlift in said flow tube above said medial area of said flow tube, said upper airlift formed to provide a pressure gradient so as to provide lift in said flow tube.

13. The bioreactor of claim 12, wherein there is further provided first and second coils concentrically mounted to said flow tube above said medial area of said flow tube, said first and second coils mounted in spaced fashion along the length of said flow tube to selectively provide a tuned electromagnetic field within and about said flow tube.

14. The bioreactor of claim 13, wherein said first and second coils comprise a Helmholtz coil, said diameter of said flow tube is about four feet, and said first and second coils are spaced about 24.5 inches apart.

15. The bioreactor of claim 12, wherein there is further provided a dome mounted to said upper end of said containment vessel, said dome being transparent to light, said dome defining a headspace above said top of said flow tube whereby matter flowing from said top of said flow tube is exposed to light from said dome.

16. The bioreactor of claim 15, wherein there is further provided a millimeter wave emitter mounted to said dome, said millimeter wave emitter formed to project millimeter waves into said headspace defined by said dome, such that flow from said top of said flow tube is exposed to said millimeter waves.

17. The bioreactor of claim 16, wherein there is further provided in said flow tube a CO2 infusion array formed to selectively infuse CO2 into said flow tube.

18. The bioreactor of claim 16, wherein said wall of said containment vessel has formed therethrough ports, each said port covered via a port cover formed of fluid impermeable, light transmissive material.

19. The bioreactor of claim 18, wherein said port further comprises an artificial light source mounted so as to project light into said interior of said containment vessel at each said port cover.

20. The bioreactor of claim 19, wherein said artificial light source comprises an LED array.

21. The bioreactor of claim 20, wherein said port cover comprises a dome having a convex side in said interior of said containment vessel, said dome also having a concave side defining an enclosure, wherein said LED array of said light source is mounted.

22. The bioreactor of claim 21, wherein said dome has a base having a flange, said flange mounted to said wall of said containment vessel, and wherein said base has mounted thereto a cover formed to protect said LED array from environmental conditions outside of said containment vessel.

23. The bioreactor of claim 22, wherein said cover has a vent formed therein to allow the passage of air exterior said containment vessel therethrough to cool said LED array.

24. The bioreactor of claim 12, wherein said upper and lower airlift each comprise first and second perforated hose coils, respectively.

25. The bioreactor of claim 1, wherein there is a ≧

10% difference in the inner diameter of said interior of said containment vessel at said lower and upper ends of said containment vessel when compared to the inner diameter of said containment vessel at its medial area, so as to provide a flow configuration wherein the longitudinal flow of matter between said inner walls of said containment vessel and said flow tube results in an increase of turbulence therein.

26. The bioreactor of claim 25, wherein said flow configuration is formed so as to facilitate the infusion of CO2 and air into the matter.

27. The bioreactor of claim 1, wherein the inner diameter of said interior of said containment vessel at said lower and upper ends is less than the inner diameter of said containment vessel at said medial area, such that longitudinal flow of matter between said inner walls of said containment vessel and said flow tube encounter an increase in turbulence.

28. The bioreactor of claim 1, wherein said inner diameter of said interior of said containment vessel at said upper and lower ends is at least 10% less than said inner diameter of said interior of said containment area at said medial area.

29. The bioreactor of claim 1, wherein the wall defining said passage of said flow tube has a light absorbent surface, and the outer surface of said flow tube has a light reflective surface.

30. The bioreactor of claim 29, wherein said inner side of said wall forming said containment vessel has a light reflective surface.

31. The bioreactor of claim 29, wherein said light reflective surface of said inner side of said wall forming said containment vessel further comprises an application of light reflective paint having situated thereupon about ¼

pound of 12-20 mesh size, airport grade glass beads being evenly spread per square foot.

32. A bioreactor, comprising:

a containment vessel having a wall having inner and outer sides forming an interior having an inner diameter, lower and upper ends, and a medial area therebetween;

a generally vertically oriented flow tube concentrically situated in said interior of said containment vessel, said flow tube forming a longitudinal passage having a bottom, a top, and a medial area therebetween;

said flow tube having laterally formed therethrough, in the vicinity of said medial area of said longitudinal passage, a medial flow aperture;

a sliding gate valve comprising a buoyant, cylindrical body formed to slidingly engage said wall of said flow tube so as to selectively block flow through said medial flow aperture upon said interior of said containment vessel being filled to a predetermined fluid level;

an auxiliary flat panel bioreactor in fluid communication with said containment vessel, said auxiliary flat panel bioreactor having a top side and an underside comprising;

first and second panels mounted in a spaced fashion to define an enclosure therebetween, said first panel formed of light permeable material, said enclosure having a length and first and second ends, said first panel defining said top side of said auxiliary flat panel bioreactor, said second panel defining said underside of said auxiliary flat panel bioreactor;

wherein said auxiliary flat panel bioreactor is situated exterior to said containment vessel, said enclosure is formed to receive a flow of liquid biomass suspension from said containment vessel, and said auxiliary flat panel bioreactor formed to facilitate the passage of said flow of liquid biomass suspension through said enclosure so as to receive light energy radiating therein.

33. The bioreactor of claim 32, wherein said auxiliary flat panel bioreactor further comprises a diffuser, said diffuser being formed to receive and diffuse gas therefrom so as to urge biomass and fluid in said liquid biomass suspension through said enclosure, while providing turbulence in said enclosure to enhance exposure of biomass in said liquid biomass suspension to said light energy as it flows through said enclosure.

34. The bioreactor of claim 33, wherein said second panel of said auxiliary flat panel bioreactor is formed of a light permeable material, and wherein there is further provided an artificial light source mounted to project light through said second panel into said enclosure, so as to radiate light energy into said enclosure.

35. The bioreactor of claim 34, wherein said first and second panels of said bioreactor comprise a layer of one-way reflective material formed to prevent light from passing out of said enclosure, said one-way reflective material formed to allow the one-way passage of light through said first and second panels into said enclosure, respectively, so as to form a reflective light chamber between said first and second panels, so as to better expose said light to any flowing matter passing therethrough.

36. The bioreactor system of claim 35, wherein there is further provided a diaphragm pump formed to provide a surging flow of liquid biomass suspension from said containment vessel to said auxiliary flat panel bioreactor, and through said first tube of said auxiliary flat panel bioreactor, so as to provide enhanced flow through said enclosure and back to said containment vessel.