Process for growing biomass by modulating supply of gas to reaction zone

• US 8,969,067 B2
• Filed: 05/20/2010
• Issued: 03/03/2015
• Est. Priority Date: 05/20/2010
• Status: Active Grant

• Current Assignee: Pond Technologies, Inc. (Pond Technologies Holdings, Inc.)
• Original Assignee: Pond Biofuels, Inc.
• Inventors: Martin, Steven C., Kolesnik, Max, Gonzalez, Jaime A.
• Primary Examiner(s): Fox, Allison
• Assistant Examiner(s): Pyla, Yvonne
• Application Number:
  US12/784,215
• Publication Number:
  US 20110287507A1
• Time in Patent Office: 1,748 Days
• Field of Search: None
• US Class Current: 435/266
• CPC Class Codes: C12M 21/02 Photobioreactors culturing algae A01G33/00, A01H4/001, C12N1/12
• CPC Class Codes: C12M 41/34 of gas
• CPC Class Codes: C12M 41/36 of biomass, e.g. colony counters or by turbidity measurements electrooptical investigation of individual particles G01N15/14, flow cytometers G01N15/1404
• CPC Class Codes: C12N 1/12 Unicellular algae; Culture media therefor as new plants A01H13/00
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02E 50/30 Fuel from waste, e.g. synthetic alcohol or diesel

Abstract

There is provided a process of growing a phototrophic biomass in a reaction zone. Gaseous exhaust material is produced with a gaseous exhaust material producing process, wherein the gaseous exhaust material includes carbon dioxide. A discharge of the gaseous exhaust material is supplied to the reaction zone and is modulated. A bypass gaseous exhaust material, being supplied to another unit operation, is also modulated.

Claims

1. A process of growing a phototrophic biomass in a reaction zone, wherein the reaction zone includes an operative reaction mixture, wherein the operative reaction mixture includes the phototrophic biomass disposed in an aqueous medium, comprising:

producing gaseous exhaust material with a gaseous exhaust material producing process, wherein the gaseous exhaust material includes carbon dioxide;

supplying reaction zone feed material to the reaction zone to effect a carbon dioxide-enriched phototrophic biomass;

exposing the carbon dioxide-enriched phototrophic biomass disposed in the aqueous medium to photosynthetically active light radiation so as to effect photosynthesis; and

modulating a discharge of the gaseous exhaust material from the gaseous exhaust material producing process based on sensing of at least one reaction zone parameter;

wherein the modulating of the discharge of the gaseous exhaust material includes both of, in parallel;

(i) modulation of a supply of the discharged gaseous exhaust material to the reaction zone feed material, wherein the discharged gaseous exhaust material which is supplied to the reaction zone feed material defines a gaseous exhaust material reaction zone supply, such that the gaseous exhaust material reaction zone supply, and the reaction zone feed material being supplied by the gaseous exhaust material reaction zone supply includes carbon dioxide; and

(ii) modulation of a supply of the discharged gaseous exhaust material to another unit operation, wherein the supply of the discharged gaseous exhaust material to the another unit operation defines a bypass gaseous exhaust material, wherein the bypass gaseous exhaust material includes carbon dioxide, and wherein the another unit operation converts the bypass gaseous exhaust material such that its environmental impact is reduced.

2. The process as claimed in claim 1;

wherein the reaction zone parameter which is sensed is at least one of;

(a) a carbon dioxide supply indication, and (b) a phototrophic biomass concentration indication.

3. The process as claimed in claim 1;

wherein the modulating of the discharge of the gaseous exhaust material is effected while the gaseous exhaust material is being produced by the gaseous exhaust material producing process.

4. The process as claimed in claim 3;

wherein the modulating of the discharge of the gaseous exhaust material is effected while the gaseous exhaust material reaction zone supply is being supplied to the reaction zone feed material.

5. The process as claimed in claim 4;

wherein the modulating of the discharge of the gaseous exhaust material is effected while the reaction zone feed material is being supplied to the reaction zone.

6. The process as claimed in claim 5;

wherein the exposing of the carbon dioxide-enriched phototrophic biomass disposed in the aqueous medium to photosynthetically active light radiation is effected while the modulating of the discharge of the produced gaseous exhaust material is being effected.

7. The process as claimed in claim 6;

wherein the reaction zone feed material is supplied to the reaction zone as a flow of reaction zone feed material through a fluid passage.

8. The process as claimed in claim 7;

wherein a flow control element is disposed within the fluid passage and is configured to selectively control the rate of flow of the reaction zone feed material by selectively interfering with the flow of the reaction zone feed material and thereby effecting pressure energy losses within the flow of the reaction zone feed material, such that the reducing of the rate of supply, or the eliminating of the supply, of the gaseous exhaust material reaction zone supply to the reaction zone feed material is effected by the flow control element.

9. The process as claimed in claim 8;

wherein the flow control element includes a valve.

10. The process as claimed in claim 8;

wherein the flow control element include a variable speed blower.

11. The process as claimed in claim 1;

wherein the reaction zone feed material is a gaseous material.

12. The process as claimed in claim 11;

wherein the reaction zone feed material includes a dispersion of gaseous material in a liquid material.

13. The process as claimed in claim 1;

wherein the another unit operation is a smokestack which is fluidly coupled to an outlet of the gaseous exhaust material producing process which effects a discharge of the bypass gaseous exhaust material, and wherein the bypass gaseous exhaust material being discharged from the outlet is disposed at a pressure which is sufficiently high so as to effect flow through the smokestack.

14. The process as claimed in claim 13;

wherein the flow of the bypass gaseous exhaust material through the smokestack is directed to a space remote from the outlet which discharges the bypass gaseous exhaust material from the gaseous exhaust material producing process.

15. The process as claimed in claim 14;

wherein the bypass gaseous exhaust material is discharged from the outlet when the pressure of the bypass gaseous exhaust material exceeds a predetermined maximum pressure.

16. The process as claimed in claim 15;

wherein the exceeding of the predetermined maximum pressure by the bypass gaseous exhaust material effects an opening of a closure element.

17. The process as claimed in claim 16;

wherein the closure element includes a valve.

18. The process as claimed in claim 2;

wherein the carbon dioxide supply indication includes a pH sensed within the reaction zone.

19. The process as claimed in claim 2;

wherein the phototrophic biomass concentration indication is provided by a cell counter.

20. The process as claimed in claim 1;

wherein, when at least a fraction of the reaction zone feed material is supplied by a gaseous exhaust material reaction zone supply, and when a carbon dioxide supply indication is sensed in the reaction zone which is above a predetermined high carbon dioxide supply value, the modulating of the discharge of the gaseous exhaust material includes;

(a) reducing the rate of supply, or eliminating the supply, of the gaseous exhaust material reaction zone supply to the reaction zone feed material, and

(b) effecting the supply, or an increase to the rate of supply, of the bypass gaseous exhaust material to the another unit operation.

21. The process as claimed in claim 1;

wherein, when a carbon dioxide supply indication is sensed in the reaction zone which is below a predetermined low carbon dioxide supply value, the modulating of the discharge of the gaseous exhaust material includes;

(a) effecting the supply, or an increase to the rate of supply, of the gaseous exhaust material reaction zone supply to the reaction zone feed material; and

(b) effecting elimination of the supply, or a decrease to the rate of supply, of the bypass gaseous exhaust material to the another unit operation.

22. The process as claimed in claim 1;

wherein, when at least a fraction of the reaction zone feed material is supplied by a gaseous exhaust material reaction zone supply, and when a phototrophic biomass concentration indication is sensed in the reaction zone which is above a predetermined high phototrophic biomass concentration value, the modulating of the discharge of the gaseous exhaust material includes;

(a) reducing the rate of supply of the gaseous exhaust material reaction zone supply to the reaction zone feed material; and

(b) increasing the rate of supply of the bypass gaseous exhaust material of the gaseous exhaust material to the another unit operation.

23. The process as claimed in claim 1;

wherein, when at least a fraction of the reaction zone feed material is supplied by a gaseous exhaust material reaction zone supply, and when a phototrophic biomass concentration indication is sensed in the reaction zone which is below a predetermined low phototrophic biomass concentration value, the modulating of the discharge of the gaseous exhaust material includes;

(a) increasing the rate of supply of the gaseous exhaust material reaction zone supply to the reaction zone feed material; and

(b) decreasing the rate of supply of the bypass gaseous exhaust material of the gaseous exhaust material to the another unit operation.

24. The process as claimed in claim 1;

wherein, when at least a fraction of the reaction zone feed material is supplied by a gaseous exhaust material reaction zone supply, and when a carbon dioxide supply indication is sensed in the reaction zone which is above a predetermined high carbon dioxide supply value, the modulating of the discharge of the gaseous exhaust material includes reducing the rate of supply, or eliminating the supply, of the gaseous exhaust material reaction zone supply to the reaction zone feed material;

and wherein, the process further comprises effecting the supply, or increasing the rate of supply, of a supplemental gas-comprising material to the reaction zone feed material, wherein the carbon dioxide concentration, if any, of the supplemental gas-comprising material is lower than the carbon dioxide concentration of the gaseous exhaust material reaction zone supply.

25. The process as claimed in claim 24;

wherein the supply rate reduction, or the elimination of the supply, of the gaseous exhaust material reaction zone supply to the reaction zone feed material effected by the modulating of the discharge of the gaseous exhaust material, co-operates with the supply of the supplemental gas-comprising material to the reaction zone feed material to effect a reduction in the rate, or the elimination, of carbon dioxide supply to the reaction zone feed material.

26. The process as claimed in claim 1;

wherein, when at least a fraction of the reaction zone feed material is supplied by a gaseous exhaust material reaction zone supply, and when a carbon dioxide supply indication is sensed in the reaction zone which is above a predetermined high carbon dioxide supply value, the modulating of the discharge of the gaseous exhaust material includes reducing the rate of supply, or eliminating the supply, of the gaseous exhaust material reaction zone supply to the reaction zone feed material;

and wherein, the process further comprises effecting the supply, or increasing the rate of supply, of a supplemental gas-comprising material to the reaction zone feed material for at least partially compensating for the reduction in supply rate of material, or the elimination of any material supply, to the reaction zone feed material effected by the modulating of the discharge of the gaseous exhaust material;

and wherein the supply rate reduction, or the elimination of the supply, of the gaseous exhaust material reaction zone supply to the reaction zone feed material effected by the modulating of the discharge of the gaseous exhaust material co-operates with the supply of the supplemental gas-comprising material to the reaction zone feed material to effect a reduction in the rate, or the elimination, of carbon dioxide supply to the reaction zone feed material.

27. The process as claimed in claim 26;

wherein the rate of carbon dioxide being supplied, if any, in the supplemental gas-comprising material, is sufficiently low such that the supply of the supplemental gas-comprising material, in co-operation with the supply rate reduction, or the elimination of supply, of the gaseous exhaust material reaction zone supply, effects a reduction in the rate of carbon dioxide being supplied to the reaction zone feed material.

28. The process as claimed in claim 26;

wherein the concentration of carbon dioxide, if any, in the supplemental gas-comprising material, is less than the concentration of carbon dioxide in the gaseous exhaust material reaction zone supply.

29. The process as claimed in claim 26;

wherein the gaseous exhaust material producing process is disposed in fluid communication with the reaction zone feed material through a fluid passage and the gaseous exhaust material reaction zone supply is supplied to the reaction zone feed material as a flow of gaseous exhaust material reaction zone supply which is flowed through the fluid passage;

and wherein the reaction zone feed material being supplied to the reaction zone is a flow of reaction zone feed material, and wherein the reducing effects a reduction in the fraction of the reaction zone feed material flow which is supplied by the gaseous exhaust material reaction zone supply flow.

30. The process as claimed in claim 26;

wherein the reaction zone feed material being supplied to the reaction zone is flowed to the reaction zone to effect the supply of the reaction zone feed material to the reaction zone;

and wherein the compensation, for the reduction in supply rate of material, or the elimination of any material supply, to the reaction zone feed material effected by the modulating of the discharge of the gaseous exhaust material, as effected by the supply of the supplemental gas-comprising material, effects substantially no change to the rate of flow of reaction zone feed material to the reaction zone.

31. The process as claimed in claim 26;

wherein the reaction zone feed material is flowed to the reaction zone and effects agitation of material within the reaction zone such that any difference in phototrophic biomass concentration between two points in the reaction zone is less than 20%.

32. The process as claimed in claim 31;

wherein the effected agitation is such that any difference in phototrophic biomass concentration between two points in the reaction zone is less than 10%.

33. The process as claimed in claim 26;

wherein the reaction zone feed material is a gaseous material.

34. The process as claimed in claim 33;

wherein the reaction zone feed material includes a dispersion of gaseous material in a liquid material.

35. The process as claimed in claim 26;

wherein the supplemental gas-comprising material is a gaseous material.

36. The process as claimed in claim 26;

wherein the supplemental gas-comprising material includes a dispersion of gaseous material in a liquid material.

37. The process as claimed in claim 26;

wherein the supplemental gas-comprising material includes air.

38. The process as claimed in claim 24;

wherein the supply, or increasing the rate of supply, of a supplemental gas-comprising material to the reaction zone feed material is effected while the modulating is being effected.

39. The process as claimed in claim 38;

wherein the supply, or increasing the rate of supply, of a supplemental gas-comprising material to the reaction zone feed material is effected while the gaseous exhaust material is being produced.

40. The process as claimed in claim 39;

wherein the supply, or increasing the rate of supply, of a supplemental gas-comprising material to the reaction zone feed material is effected while the modulating is being effected while the reaction zone feed material is being supplied to the reaction zone.

41. The process as claimed in claim 40;

wherein the exposing of the carbon dioxide-enriched phototrophic biomass disposed in the aqueous medium to photosynthetically active light radiation is effected while the supply, or increasing the rate of supply, of a supplemental gas-comprising material to the reaction zone feed material is being effected.

42. The process as claimed in claim 26;

wherein the supply, or increasing the rate of supply, of a supplemental gas-comprising material to the reaction zone feed material is effected while the modulating is being effected.

43. The process as claimed in claim 42;

wherein the supply, or increasing the rate of supply, of a supplemental gas-comprising material to the reaction zone feed material is effected while the gaseous exhaust material is being produced.

44. The process as claimed in claim 43;

wherein the supply, or increasing the rate of supply, of a supplemental gas-comprising material to the reaction zone feed material is effected while the modulating is being effected while the reaction zone feed material is being supplied to the reaction zone.

45. The process as claimed in claim 44;

wherein the exposing of the carbon dioxide-enriched phototrophic biomass disposed in the aqueous medium to photosynthetically active light radiation is effected while the supply, or increasing the rate of supply, of a supplemental gas-comprising material to the reaction zone feed material is being effected.

46. The process as claimed in claim 26;

wherein the modulating of the discharge of the gaseous exhaust material further effects the supply, or an increase to the rate of supply, from the discharged gaseous exhaust material, of a bypass gaseous exhaust material to another unit operation which converts the bypass gaseous exhaust material such that its environmental impact is reduced.

47. The process as claimed in claim 46;

wherein the another unit operation is a smokestack which is fluidly coupled to an outlet of the gaseous exhaust material producing process which effects the discharge of the bypass gaseous exhaust material, and wherein the bypass gaseous exhaust material being discharged from the outlet is disposed at a pressure which is sufficiently high so as to effect flow through the smokestack.

48. The process as claimed in claim 47;

wherein the flow of the bypass gaseous exhaust material through the smokestack is directed to a space remote from the outlet which discharges the bypass gaseous exhaust material from the gaseous exhaust material producing process.

49. The process as claimed in claim 1;

wherein the reaction zone is disposed in a photobioreactor.

50. The process as claimed in claim 1;

wherein the sensing of at least one of the at least one reaction zone parameter is effected in the reaction zone.