Note: Descriptions are shown in the official language in which they were submitted.
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SYSTEMS AND METHODS OF PRODUCING COMPOSITIONS FROM THE NUTRIENTS
RECOVERED FROM WASTE STREAMS
FIELD OF THE INVENTION
[0001] The present invention relates to algae growth systems and in particular
to Systems and
Methods of Producing Compositions from the Recovered Nutrients from Waste
Streams.
BACKGROUND
[0002] Waste management, e.g., livestock manure, food wastes, beverage wastes,
food
byproducts, and nutrient runoff, are large environmental and societal
concerns.
[0003] Livestock manure management is a global issue, with the U.S. Department
of Agriculture
estimating in 2012 that more than 335 million tons of "dry matter" waste (the
portion of waste
remaining after water is removed) was being produced annually on farms in the
United States.
Animal feeding operations annually produce about 100 times more manure than
the amount of
human sewage sludge processed and existing dairy manure management practices
are unable to
mitigate the environmental impact from nutrient runoff (a byproduct of
anaerobic digesters).
Food waste management is another large-scale global problem as about one-third
of food is
wasted worldwide. Food waste is estimated at between 30 to 40 percent of the
food supply in the
United States.
[0004] The successful role of algae in wastewater treatment has been
documented since the early
1950s, and algal wastewater treatment systems are known to utilize the extra
nutrients including
nitrogen, phosphorus, potassium, heavy metals and other organic compounds from
wastewater.
For example, an algal turf scrubber system feeding algae a diet of dairy
manure can recover over
95% of the nitrogen and phosphorous in the manure wastewater. Additionally,
lipid/oil
productivity occurs in algal wastewater treatment systems, but there are few,
if any, known
robust algae strain(s) for oil production that use wastewater as a primary
feedstock. For example,
a polyculture (dominated by Rhizoclonium sp.) used in algal turf systems for
treating dairy and
swine wastewater had very low lipids/oil content (fatty acids contents of 0.6%
to 1.5% of dry
algae weight) and other researchers have reported 2.8 g/m2 per day of lipid
productivity from
algal polyculture combined with dairy wastewater treatment.
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[0005] Mass cultivation of algae has also been used for creating nutritional
supplements,
fertilizer, and food additives. Additionally, commercial growth of algae has
been explored to
create biologically-derived energy products such as biodiesel, bioethanol, and
hydrogen gas. As
a biofuel feedstock, algae provide multiple environmental benefits and
presents significant
advantages over traditional plants/crops used for biofuel production (e.g.,
corn, sugarcane,
switch-grass, etc.). For example, unlike traditional food crops that are being
used to produce
biofuels (e.g., corn, sugarcane, etc.), algae does not compete with food and
water resources; it
grows significantly faster than traditional crops used for biodiesel; algae
produce up to 300 times
more oil than traditional crops on an area basis; algae fuel has properties
(low temperature and
high energy density) of which make it suitable as jet fuel; and algae can be
produced so as to
provide a nearly continuous supply of fuel. Moreover, algae can treat
industrial, municipal and
agricultural wastewaters, capture carbon-dioxide, and provide valuable
byproducts, such as, but
not limited to, protein-rich feed for farm animals, organic fertilizer, and
feedstock for producing
biogas.
[0006] Algal biomass can accumulate up to 50% carbon by dry weight, therefore
producing 100
tons of algal biomass which fixes roughly 183 tons of CO2¨providing a
tremendous potential to
capture CO2 emissions from power plant flue gases and other fixed sources for
growing algae
biomass. Ideally, biodiesel from algae can be carbon neutral, because all the
power needed for
producing and processing the algae could potentially come from algal biodiesel
and from
methane produced by anaerobic digestion of the biomass residue left behind
after the oil has
been extracted.
[0007] Algae's other byproducts can also be beneficial. For example, the value
of algae as food
was explored as early as 1950s, and some have demonstrated the concept by
raising baby
chickens to adults on twenty percent (20%) algae fortified feed (grown on
pasteurized chicken
manure). The antibiotic Chlorellin extracted from Chlorella during World War
II marked the
start of algae based pharmaceutical and nutraceutical industry that led to the
Japanese Chlorella
production facilities during 1960s, further leading to current production of
Chlorella, Spirulina,
Dunaliella and Hematococus at commercial scales. Fertilizers from algae have
also shown
equivalence to commercial organic fertilizers in terms of plant mass and
nutrient content.
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[0008] Despite all of the aforementioned benefits, algae biomass production
and the production
of algal oil (i.e., biofuels from algae) are primarily hampered by the high
cost of producing algae
biomass (currently either requiring large amounts of land/water and/or large
sterile facilities).
There have been attempts to offset this high cost by using the various traits
of algae to their
greatest benefit. For example, biofuel production from algae has been combined
with waste-
water treatment (as discussed above) and has been shown to be 40% more cost
effective than the
best conventional alternatives, but still has not been economically viable due
to low lipid
production. As another example, entities have attempted to vary the type of
cultures used¨for
example, algae monoculture (requiring sterile conditions) versus polyculture-
based wastewater
treatment. However, the results of these trials have not proven themselves.
Other disadvantages
of current algae biomass production include, but are not limited to, the
availability of low cost
throughput sugar feed-stocks for growing algae, treating effluent created
during production, and
the requirement of nitrogen and phosphorus supplements. Until such time as
these algae
production related issues are solved, production of oil feedstock from algae
is likely to remain
commercially infeasible.
[0009] For this reason, the system and process disclosed herein addresses the
challenges
involved in materializing the cost-efficient algae-based on a robust, easily
adaptable, sustainable,
environmentally friendly system that is capable of growing algae biomass at
commercial scales
for fertilizer, animal feed, water, biofuel, and other byproducts. The
symbiotic algae system and
process disclosed herein also holds great potential for farms, industries, and
municipalities
especially dairy farms and food & beverage industries, because the system
allows these entities
to more efficiently and effectively meet government standards for handling and
recycling of
wastes.
SUMMARY
[0010] In a first exemplary aspect, there is disclosed a symbiotic algae
system comprising a
pretreater suitable for producing a first effluent with reduced odor and
biochemical oxygen
demand; a first algal growth component fluidly coupled to the pretreater and
receiving the first
effluent, wherein the first algal growth component includes a heterotrophic
algal growth strain,
and wherein the first algal growth component produces a second effluent having
nutrients and an
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off-gas; and a second algal growth component fluidly coupled to the first
algal growth
component, and the second algal growth component including at least one algal
growth strain
from the group of: a photoautotrophic algal growth strain, a mixotrophic algal
growth strain, and
a heterotrophic algal growth strain, and wherein the second algal growth
component receives, as
an input, the second effluent and the off-gas and produces a third effluent.
[0011] In another exemplary aspect, there is disclosed a symbiotic algae
system comprising: a
pretreater for producing a first effluent with reduced odor and biochemical
oxygen demand; a
first algal growth component, wherein the first algal growth component
includes a heterotrophic
algal growth strain, and wherein the first algal growth component produces a
second effluent
having nutrients and an off-gas; and a second algal growth component fluidly
coupled to the first
algal growth component, wherein the second algal growth component includes at
least one algal
growth strain from the group of: a photoautotrophic algal growth strain, a
mixotrophic algal
growth strain, and a heterotrophic algal growth strain, and wherein the second
algal growth
component receives, as an input, the second effluent and the first off-gas and
produces a second
effluent and a second off-gas; and wherein the second effluent and the second
off-gas are
received as inputs to the first algal growth component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For the purpose of illustrating the invention, the drawings show
aspects of one or more
embodiments of the invention. However, it should be understood that the
present invention is not
limited to the precise arrangements and instrumentalities shown in the
drawings, wherein:
FIG. 1 is a block diagram of an exemplary symbiotic algae system according to
an embodiment
of the present invention;
FIG. 2 is a block diagram of an algal core suitable for use with an exemplary
symbiotic algae
system such as the systems shown in FIGS. 1 and 5;
FIG. 3 is a block diagram of another algal core suitable for use with an
exemplary symbiotic
algae system such as the systems shown in FIGS. 1 and 5;
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FIG. 4 is a block diagram of another algal core suitable for use with an
exemplary symbiotic
algae system such as the systems shown in FIGS. 1 and 5;
FIG. 5 is a block diagram of a portion of an exemplary symbiotic algae system
according to
another embodiment of the present invention;
FIG. 6 is a chart of algal cell density showing the optical density over time
for a test core
according to an embodiment of the present invention and a control;
FIG. 7 is a block diagram of a portion of an exemplary symbiotic algae system
suitable for
removing contaminants according to another embodiment of the present invention
FIG. 8 is a block diagram of an exemplary process of removing contaminants
from a waste
stream according to an embodiment of the present invention;
FIG. 9 is a table showing prior art energy returns for biodiesel using various
feed-stocks;
FIG. 10 is a block diagram of an exemplary symbiotic algae system according to
another
embodiment of the present invention;
FIG. 11 is a block diagram of an exemplary symbiotic algae system according to
yet another
embodiment of the present invention;
FIG. 12 is a block diagram of a portion of an exemplary symbiotic biomass
production system
integrated with struvite crystallization system according to an embodiment of
the present
invention;
FIG. 13 a block diagram of a portion of an exemplary symbiotic biomass
production system
integrated with a dissolved air floatation system according to an embodiment
of the present
invention;
FIGS. 14A-D are photographs of exemplary plants provided certain amounts of
nutrients
produced by a symbiotic algae system according to an embodiment of the present
invention;
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FIG. 15 is a block diagram of a portion of an exemplary symbiotic biomass
production system
integrated with thermal decomposition system according to an embodiment of the
present
invention;
FIGS. 16A-C are photographs of tests of lettuce growth conducted on certain
soil mixes; and
FIG. 17 is a schematic diagram of an exemplary canal structure suitable for
growing algae
according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0013] Systems and methods disclosed herein can create useful compositions
from the nutrients
recovered from waste streams, such as, but not limited to, fertilizers for
plant growth, soil
fertility, and protein substitute for feed or food. The nutrients can be
recovered by using one or
more or combination of following; biological treatment in the form of biomass
such as algae, as
byproducts of mechanical and/or chemical separation of a waste stream, or
chemical treatment.
[0014] Systems and methods disclosed herein use nutrients from various waste
streams to
produce compositions of valued byproducts such as fertilizer, animal feed,
fuel, recycled water
etc., where algae biomass production is one of the components. In certain
embodiments
compositions of fertilizer(s) or soil enhancement(s) for plant nutrition and
soil fertility are
created by using one or more waste stream processing byproducts. The
byproducts can be
produced through mechanical and/or chemical and/or biological and/or via
anaerobic digestion
or co-digestion processing of one or more waste components including, but not
limited to:
manure from livestock or animals, food waste from residential, or commercial
or non-profit
operations, beverage, byproduct(s) of beer or wine or alcohol or beverages or
spirits,
manufacture processes, source separated organic waste, organic byproducts of
manufacturing
processes, glycerol, glycerin, fats, oils, lipids, grease, yard waste, wood,
biosolids, municipal
material, digestible organic materials, and any combination thereof.
[0015] The byproducts of waste stream processing can include one or more or a
combination of
organic material including, but not limited to, separated and/or digested
solids, fibers, non-fibers,
effluent, exhaust gas(es), and heat. The byproducts can contain nutrient(s),
either or combination
of nitrogen, phosphorus, potassium and any or more of other elements such as
Ca, Mg, Na, Al,
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Fe, Mn, B, Cu, Zn, S, Pb, Cd, As, etc. The composition(s), created by the
systems and methods
disclosed herein, for plant nutrition and soil fertility include(s)
predominantly aquatic biomass
(such as algae, naturally occurring microorganisms, macrobial biomass like
duckweed) grown
with or without the byproducts of anaerobic digestion from the sources as
described above.
Systems and methods disclosed herein can also produce organic and/or non-
organic byproduct(s)
via mechanical and/or chemical and/or biological processing means such as, but
not limited to,
solids separation; centrifugation; dissolved air floatation; flocculation;
struvite formation;
enhanced biological phosphorus removal; crystallization of magnesium ammonium
phosphate,
calcium phosphate, incineration, bio-ammonium sulfate crystals and/or solids;
combined
nitrogen and phosphorus removal technologies; nitrification; denitrification;
nitrogen and/or
ammonia stripping with or without solid separation; separation of phosphorus
and/or nitrogen
and/or potassium rich solids; or biological conversion to non-reactive
nitrogen and/or
phosphorus. In some embodiments nitrogen and/or phosphorus may be present
along with other
non-predominant elements or compounds in various forms, structures etc. pH
and/or nutrient
balancing can be advanced by the addition of, for example, acidic or basic
matter or a
combination in nature such as lime, ash, tree parts, compost from any organic
sources some
described above.
[0016] In some of the embodiments described herein, systems and methods are
disclosed for
removing nutrients from agricultural and industrial waste streams so as to
produce valued
products such as fertilizer for plant growth and soil fertility, and protein
substitute or supplement
for animal feed. The systems and methods can, in certain embodiments, remove
nutrient nitrogen
and/or phosphorus in relatively high quantities ¨ characteristics that limit
other currently known
technologies. Certain embodiments discussed herein can provide customizable
compositions of
valued products to serve needs of both front and/or end users and optionally,
provide additional
organic matter to support biological activity, build soil fertility,
compensate for nutrient loss by
crop harvest or runoff, slow release features to reduce nutrient runoff into
waterways, and a wide
variety of other applications.
[0017] A symbiotic algae system according to present disclosure provides a
cost-efficient means
of producing algae biomass for many applications, such as, but not limited to,
as feedstock for
biofuel manufacture and desirably impacts alternative/renewable energy
production, nutrient
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recovery from waste streams, and valued byproducts production (nutraceuticals,
pharmaceuticals, animal feed etc.). A symbiotic algae system as discussed
herein is an integrated
systems approach to wastewater treatment, algal strains selection for oil
production, CO2 capture
or nutrient capture from heterotrophic processes, and recycle of algal-oil
extraction waste as
feedstock for biogas production. Embodiments of a symbiotic algae system as
discussed herein
present an economically viable algae production system and process that allows
algae-derived
biofuels to compete with petroleum products in the marketplace.
[0018] A symbiotic algae system as discussed herein is, at a high level, a
scalable process for
cultivating algae biomass, in which a heterotrophic (i.e., non-light
dependent) algal growth strain
is used to provide carbon dioxide and/or effluent to a photoautotrophic or
mixotrophic or a
combination of the three cultivation processes (i.e., photoautotrophic,
mixotrophic, and
heterotrophic) while concomitantly producing algae biomass or lipids for
biofuel production. In
certain embodiments, the photoautotrophic or mixotrophic or heterotrophic
cultivation portion of
the symbiotic algae system may result in the cultivation of additional algae
biomass, but could
include (alternatively or additionally) the cultivation of any
photoautotrophically or
mixotrophically grown microbial plant matter that requires carbon dioxide
and/or effluent
containing nutrients, such as nitrogen, phosphorus and organic carbon. As will
be discussed in
more detail below, the symbiotic algae system can efficiently use nutrients
from both
commercial and/or other waste streams for the production of lipids for use
with biofuels, and as
such, the energy return on investment scenarios are significantly higher than
previously
considered possible. This symbiotic algae system provides a robust scalable
option which has
improved cost efficiencies due to production of additional desirable
byproducts such as fertilizer.
[0019] Turning now to the figures, and specifically with reference to FIG. 1,
there is shown a
symbiotic algae system (SAS) 100. In an exemplary embodiment, SAS 100
includes, at a high
level, a waste nutrient preparation sub-system 104, an algal culturing system
108, an algal
harvesting system 112, an algal biomass processing system 116, and a
byproducts system 120.
[0020] Waste nutrient preparation sub-system 104 is generally configured to
treat incoming
feedstocks (e.g., manure, municipal waste) for the rest of SAS 100. The design
and configuration
of waste nutrient preparation sub-system 104 depends on the desired inputs for
SAS 100. As
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shown in FIG. 1, waste nutrient sub-system 104 includes three inputs: an
effluent input 124, a
water input 128, and a waste input 132. Effluent input 124 can generally be
any nutrient rich
liquid waste before or after single or multiple pre-treatments, for example,
dairy farm effluent,
agricultural wastewater streams, brewery liquid waste streams, municipal
waste, food waste, etc.
Effluent input 124 is fed into a separator 136 that separates the effluent
solids and liquids, using
methods such as settling, filtration, or via centrifugal separators. The
solids can then be fed to a
solids treatment unit 140, such as a digester, which can, among other things,
break down the
solids into a feed stream suitable for further use within SAS 100, such as a
source of carbon
dioxide and sugars, or into other byproducts (e.g., biogas, fertilizers,
etc.). Solids treatment unit
140 can also accept waste input 132 for processing solids treated by unit 140.
The output of
solids treatment unit 140 and the liquid effluent separated by separator 136
may be combined
with fresh water input 128 to prepare the feedstock for algae culturing system
108 that includes
one or more algae growth components (AGC) 152, e.g., AGC 152A and AGC 152B.
[0021] In an exemplary embodiment, waste nutrient preparation sub-system 104
is a manure
settling and solid's preparation unit that outputs liquid manure waste to
algal culturing system
108. In this embodiment, manure is combined with water run-off (e.g., fresh
water input 128)
and collected in a large separation tank (e.g., separator 136). The denser
solids are allowed to
sink to the bottom (or in certain embodiments are mechanically separated) and
the output liquid
manure water is pumped from the tank. In an exemplary embodiment, solid
wastes, for example,
ligno-cellulosic material such as grain spoilage or grasses, is pretreated in
solids treatment unit
140 with or without manure effluent to prepare the nutrients (e.g., different
forms of nitrogen or
phosphorus or sugars or organic carbon) for algal culturing in algae culturing
system 108.
[0022] Algal culturing system 108 is generally configured to grow algal
biomass from numerous
nutrient and/or waste streams. In an exemplary embodiment, algal culturing
system includes an
algal core 156 (FIG. 2), which can include an AGC 152A that is coupled to, and
mutually
supports, an AGC 152B. In an exemplary embodiment, AGC 152A is an organic
carbon source
fed heterotrophic algae and AGC 152B is one or more of a photoautotrophic,
mixotrophic, and
heterotrophic algae. In general, heterotrophic algal production produces
higher amounts of
oil/lipids compared to its lighted dependent counterpart (e.g., mixotrophic,
photoautotrophic),
however it is limited in its ability to capture nutrients or other desired
extracts and also generates
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effluent that typically requires treatment. Algal cultivating system 108
combines the two
complementary approaches thereby providing a system that can produce high
amounts of
oil/lipids and can capture nutrients for byproducts such as fertilizer
production that can offset the
costs of algal biomass production. For example, the algae Chlorella vulgaris
can remove up to
about 20.8% of phosphate under autotrophic conditions, up to about 17.8% under
heterotrophic
conditions, and up to about 20.9% under mixotrophic conditions after 5 days
when grown in
synthetic wastewater. Algal culturing system 108, in certain embodiments
described herein, can
capture the remaining nutrients left after the heterotrophic algal growth
stage and recycles these
nutrients for the autotrophic/mixotrophic algal growth and vice versa.
Additionally, algal
culturing system 108 can also be designed to recycle the CO2 produced as a
result of
heterotrophic mode of algal growth to the autotrophic/mixotrophic growth, and
can recycle the
oxygen produced by the autotrophic/mixotrophic growth for heterotrophic
growth. The recycling
of nutrients for different trophic growth provides additional cost offsets
made possible via algal
culturing system 108.
[0023] As discussed in more detail below, the design of algal core 156
determines the amount of
algae produced in AGC 152B based on the amount of CO2 produced by AGC 152A or
vice
versa with oxygen production by AGC 152A fed to AGC 152B. For example, if AGC
152A
produces about 1.8 tons of CO2, one would expect that up to about 1 ton of dry
algae biomass
would be produced by AGC 152B.
[0024] AGC 152A has the advantage of accepting a myriad of inputs. For
example, and as
described previously, AGC 152A can use liquid manure waste as in input, or can
use organic
carbon from commercially available clean sources (e.g. sugars) or other waste
streams, such as
but not limited to, grains spoilage from farms, brewery waste, liquids
containing sugars from
food waste, industrial wastes, or farm operation wastes, or a mixture of
different wastes. Algal
biomass production at AGC 152A can be maximized by using the naturally
occurring or
genetically enhanced algae strains, monoculture or polyculture, and/or other
microbial strains
such as bacteria and/or fungi that is best suited for the feedstock (e.g.
sugars available from
market or from waste sources) available at the target location. In other
words, certain algae do
better with certain carbon inputs than others. In an exemplary embodiment, the
algae, Chlorella
vulgaris, has been successfully cultured in dairy manure effluents. In another
embodiment, AGC
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152A can use and produce non-algae strains, such as the fungal strain,
Trichoderma reesei, for
converting aforementioned throughput feedstock into byproducts.
[0025] In an exemplary embodiment, AGC 152A includes heterotrophic algae,
which is known
to produce dense algae growth and a relatively high amount of useful
byproducts. Heterotrophic
algae can be grown in fermenter(s), or closed or open system(s), or a
combination or a hybrid
form of the aforementioned. Standalone growth of heterotrophic algae is
scalable in large sized
vessels (such as, but not limited to, fermenters), and under heterotrophic
growth conditions,
respiration rates equal or exceed the theoretical minimum cost of biomass
synthesis and biomass
synthesis can achieve nearly the maximal theoretical efficiency.
[0026] One of the outputs (in addition to generated algal biomass for lipid
extraction) of AGC
152A is an off-gas, CO2, which is generated as a result of algae respiration
due to organic uptake
of carbon. The CO2 generated by AGC 152A is used as an input for AGC 152B.
[0027] AGC 152B is designed to accept the output (which are typically
byproducts) of AGC
152A. As such, AGC 152B can be a photoautotrophic, a mixotrophic, or a
combination of both
photoautotrophic and mixotrophic production systems of algae fed by the CO2
produced by
AGC 152A. AGC 152B can take the form of open, closed, or hybrid systems of
algae growth and
therefore can be implemented by various methodologies, such as, but not
limited to, a tank, a
bag, a fermenter, a tubular vessel, a plate, and a raceway, of any shape,
size, or volume.
[0028] In an exemplary embodiment, AGC 152B uses clean sources of additional
nutrients or
captures nutrients from waste or wastewater streams, for example, but not
limited to,
anaerobically or aerobically digested effluent from dairy farms, industrial
operations such as
breweries, food waste, municipal waste, etc. The CO2 input stream from various
industrial
operations, such as flue gases, supplied to second algal growth component 312
may contain other
nutrients that promote algae biomass growth. While AGC 152B has been
previously described as
one or more of a photoautotrophic, mixotrophic, and heterotrophic algal
growth, it could also
include the cultivation of any biomass that requires the addition of inorganic
carbon (CO2)
and/or organic carbon and/or nutrients (such as nitrogen and phosphorus and
other micro or
macro nutrients) for its growth.
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[0029] In order to size algal core 156 (and ultimately determine an estimate
of the total expected
biomass (TEB) production of the system), the amount of algal biomass
producible from AGC
152A at the site is determined based on the amount and type of throughput
feedstock available,
e.g., the amount available from on-site sources, brought from off-site
sources, or combination of
the two, to grow the respective algae type used in AGC 152A. For example, if
the feedstock is
nitrogen rich, algal types that may be paired with this feedstock include
Chlorella vulgaris,
Chlamydomonas reinhardtii, and Scenedesmus abundans. Alternatively, if the
feedstock is
phosphate rich, the algal types that may be paired with this feedstock include
the bacteria
Acinetobacter calcoaceticus or Acinetobacter johnsonii. Based upon the
expected algal biomass
producible from AGC 152A, an amount of CO2 available to AGC 152B from AGC 152A
can be
determined. The available CO2 and the amount of feedstock available to AGC
152B is
determinative of the amount of biomass producible of AGC 152B. The TEB can
then be
determined as the sum of the algal biomass produced at AGC 152A and the
biomass produced at
AGC 152B.
[0030] The amount of biomass producible by either growth component, i.e., AGC
152A and
AGC 152B, will be heavily influenced by the specific algae chosen for each
respective
component, and in the case of AGC 152B, the type of algae chosen. For example,
a mixotrophic
algal growth system requires less CO2 because it requires greater organic
carbon uptake when
compared to a phototrophic system. Knowing the type of algal system chosen for
AGC 152B
(and the specific algae) can be used to determine the size or volume required
for AGC 152B
when implemented in the form of, for example, a closed photobioreactor, an
open tank, a
raceway, or a pond system. For example, for an output of 1000 tons of
Chlorella vulgaris grown
in AGC 152B (e.g. a photobioreactor) we would need at least 1800 tons of CO2.
That means
we'll have to setup the AGC 152B system of the volume that can grow enough
heterotrophic
biomass that can produce 1800 tons of CO2, because it is established fact that
the
photoautotrophic algae requires about 1.8 tons of CO2 to produce 1 ton of
algae. In case of
mixotrophic algal production, the CO2 requirement could be about 10 times
lower.
[0031] In another embodiment the size of algal core 156 can be deduced
inversely, e.g., first the
maximum amount of biomass producible via AGC 152B on the site is determined
(usually
space/volume limited) based upon the type of algal system, inputs, and
space/footprint available,
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then the CO2 requirements of the AGC 152B are determined, which can then be
used to
determine the composition and size of AGC 152A.
[0032] In yet another exemplary embodiment of algal core 156, an oxygen rich
air supply from
AGC 152A (when implemented as a photobioreactor as a result of photosynthesis
by
photoautotrophic or mixotrophic algae) is fed into AGC 152B (when implemented
as a
heterotrophic reactor to support growth of heterotrophic algae). This
arrangement solves a major
well-known constraint in closed photobioreactor systems caused by excessive
oxygen production
which has an adverse effect on the algae growth inside the photobioreactor.
[0033] In a further embodiment, an AGC 152A feeds AGC 152B while AGC 152B
feeds
AGC152. For example, AGC 152A may feed CO2 to AGC 152B, while AGC 152B,
concomitantly, feeds 02 to AGC 152B. Additional CO2 or 02 can be fed to the
respective
components for additional biomass production and carbon capture as desired.
[0034] Of the many advantages offered by SAS 100 and specifically by algal
core 156, is the
scalable nature of the system. Scalability is enhanced because heterotrophic
algae (i.e., AGC
152A) is capable of dense growth when compared to photoautotrophic algae and
certain
mixotrophic algae. While density allows for greater biomass production per
volume,
heterotrophic algal growth in AGC 152A produces an off-gas, CO2, and effluent
containing
nitrogen, phosphorus, and other components requiring treatment before
discharge. However, the
need and concomitant expense of treatment can be mitigated (or even eliminated
in certain
embodiments) by incorporating AGC 152B because the second algal growth
component uses the
CO2 and effluent created by the AGC 152A, thus significantly reducing waste
treatment costs
while producing additional algal biomass.
[0035] While algal core 156 has been described above as a part of a larger
system, e.g., SAS
100, algal culturing system 108, etc., it can also be implemented as a
standalone system.
[0036] As shown in FIG. 3, an algal core 200 can also use post algal harvest
liquid effluent
obtained from AGC 204A as an input for AGC 204B so as to provide an additional
supply of
nutrients.
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[0037] In yet another embodiment of algal core 200, and as shown in FIG. 4, a
first AGC
provides nutrients, but little if any (optionally) CO2 to a second AGC. This
embodiment may be
useful at sites where other means of CO2 capture, e.g., fossil fuel emissions
capture, are
available. Advantageously, using an algal core of this embodiment may also
assist a CO2
emitting facility keep CO2 emissions within emission limits as the excess CO2
can be fed to one
of the AGC's.
[0038] Another embodiment of algal core, algal core 300, is shown in FIG. 4.
In this
embodiment, algal core 300 includes a pair of AGC's, AGC 304A and 304B. AGC
304B is
optionally fed with various sources of CO2 from either onsite resource 308,
off-site resource
312, or from AGC 304A, or combinations of two or more of these CO2 sources.
For example, at
a dairy farm, the anaerobically digested effluent containing nitrogen and
phosphorus is on-site
resource. The supplementary nutrient source from off-site could be the
effluent from a creamery,
cheese factory etc. FIG. 4 also shows AGC 304B being fed with additional
sources of nutrients
from either onsite resource 316 or off-site resource 320, including, but not
limited to industrial
waste, brewery waste and/or surplus, food waste and/or surplus, farm waste
and/or surplus,
and/or municipal waste.
[0039] Returning now to a discussion of FIG. 1, algal harvesting system 112 is
used to collect
the algal biomass generated by algal culturing system 108. In an exemplary
embodiment of algal
harvesting system 112 includes one or more solid separators 160, e.g., solid
separator 160A and
160B, and a nutrient tank 164. Whether or not the output of AGC 152A or 152B
should be sent
to a separator 160 is determined by the type of output produced by the AGC. In
an exemplary
embodiment, and as shown in FIG. 1, AGC 152A produces a relatively low
concentration algal
biomass and thus separator 160A is used to concentrate the output of the AGC.
In contrast, in an
exemplary embodiment, AGC 152B produces a relatively concentrated algal
biomass output that
can be sent directly to a biomass processor 168 (described in more detail
below).
[0040] When algal harvesting system 112 is in use, algae biomass from AGC 152A
is provided
to solid separator 160A, which in this embodiment is a settling tank that
allows the algae mass to
settle to the bottom of the tank. In this embodiment, the bottom quarter of
the settling tank (or so)
is then physically separated from the rest of the settling tank's contents.
The top 3/4 of the settling
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tank (generally a liquid layer) is pumped out of solid separator 160A (and can
be re-fed into
either AGC 152A or AGC 152B, or sent to algal biomass processing system 116,
as discussed
below) leaving only the bottom algae concentrate which can be subsequently
removed.
[0041] Algal solids (also referred to as concentrate) separated out by algae
harvesting system
112 are sent to algal biomass processing system 116, which can be a standalone
unit or a
combination of Centrifugation, Filtration, Drying, Gravity settling, Microbial
or Chemical based
biomass aggregation, Flocculation and Sedimentation etc., to concentrate the
algal solids. As
shown in FIG. 1, algal biomass processing system 116 includes a pair of
biomass processors 168
(biomass processors 168A and 168B). In an exemplary embodiment, biomass
process is
implemented as a separation funnel tank equipped with electrodes. In this
embodiment, the algae
concentrate from algal harvesting system 112 is gravity fed into the
separation funnel tank. A
current is then run through the algal concentrate, via the electrodes, causing
individual algae cells
to burst thereby releasing the lipids inside. The mixture within the
separation funnel tank can
then be allowed to separate into three layers, a solid layer (also referred to
as "cake" layer), a
water layer, and a lipid layer. The separation funnel tank can then be used to
individually remove
each layer for further processing or use. In another exemplary embodiment,
biomass processing
system 116 harvests algae from man-made water collection structure such as
tanks, pits, ponds
etc., or natural water bodies such as ponds, tributaries, lakes etc. in
addition to being a part of
SAS 100. The harvested algae can be become part of the algae cake and/or
processed for
different byproducts production such as fertilizer. In exemplary embodiments,
biomass
processing unit 116 is implemented as a centrifuge, or as a unit that is
immersed or floats on
water to harvest biomass. For instance, a biomass processing system 116 can be
installed at a
farm that has nutrient runoff collection pits installed, which captures farm
runoff and thereby
naturally produce additional algae and microbes. A biomass processing unit 116
can harvest
these algae and microbes and add them to the algae cake. Algae cake with or
without the addition
of wild or naturally occurring algae can be dried or mixed with additional
biomass for
conversion into biofuel. In some of the instances of biomass processing unit
116 the algae cake is
densified by the addition of a secondary material or a mix of materials such
as sawdust, hay,
grasses, pelletization or pucks waste or surplus, lumber waste or surplus,
wood waste, or surplus
etc. These densification processes may be beneficial to the renewable diesel
production
processes described below, to the formation of a storable form of fertilizer,
or for the creation of
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combustible algal pellets for burning in gasifiers for heat. In some
instances, algae cake alone or
mixed with one or several materials, as described above, is pelletized or
prepared into pucks,
briquettes, pellets, etc., thereby providing increased storability. In another
embodiment, algae
cake is mixed with grasses grown on wasteland, or in buffer zones for
capturing nutrients, e.g.,
miscanthus, switchgrass, etc., and then is formed into pellets, briquettes,
pucks, etc.
[0042] Byproducts system 120 further treats the outputs received from algal
biomass processing
system 116. In an exemplary embodiment, from the lipid layer, crude algae oil
is extracted with a
solvent and a catalyst through a suitable process (chemical or non-chemical)
at biofuel processor
172 so as to produce biodiesel and glycerol. In another exemplary embodiment,
algae cake is
converted into different forms of marketable fertilizer (either or both liquid
and solid types). The
solid fertilizer can be made into different forms such as powder, granular,
pelleted, etc. and can
include different proportions of nitrogen, phosphorous, and potassium
(commonly combined and
referred to as N-P-K). Producing algae fertilizer with marketable N-P-K
concentrations has
proved elusive. However, in certain embodiments of SAS 100, different algae
types
(monocultures, polycultures or aggregations of naturally occurring algae with
or without other
microbes or components), capable of capturing different fertilizer
constituents (e.g., N, P, K), are
grown separately either in the looped reactor or in combined or standalone
autotrophic,
mixotrophic or heterotrophic reactors or open ponds. Harvested algae can then
be mixed in
different proportions to obtain the marketable equivalent compositions of N-P-
K, for example as
in, Alfalfa meal (N-P-K: 2-1-2); Soymeal (7-2-1); and chicken manure (1.1-0.8-
0.5). Algae
fertilizer can also be enhanced by blends of different commercially or locally
available materials
for example, by adding trace minerals for creating algae-based seed starting
mixes, or by adding
potassium for creating certain desirable N-P-K composition. Granular
fertilizer can be made
using fertilizer processor 176, which, in an exemplary embodiment is a
commercially available
granulating machine. In an exemplary embodiment, algal cake with sufficient
moisture is dried
prior to granulation. It has been reported that solid form of fertilizer
applications improve crop
growth by providing the captured nutrients in a relatively stable and storable
form, which is not
possible with application of liquid manure on the land via manure spreader.
This inefficiency
exists, because there are only few time windows available for liquid manure
spreading during the
crop growth. However, using a storable, granulated form of algal-based
fertilizer provides
flexibility of application during the times when manure spreader cannot be
used, such as for
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dressing the corn plants at the appropriate stage of their development. An
environmental benefit,
among others, of removal of nutrients via algal fertilizer is the reduction of
nutrients runoff into
natural water bodies. Moreover, cost offsets would be economically beneficial
as fertilizer
production produces an income stream for the farms or other businesses.
[0043] In yet another embodiment of byproducts system 120, biofuel processor
172 can convert
algal biomass directly from algal culturing system 108, or through algal
harvesting system 112,
or algal biomass processing system 116 into 'renewable diesel' and byproducts
via
hydrogenation (treatment with addition of hydrogen) via processes such as, but
not limited to, a)
hydrothermal processing (for instance, by reacting the biomass on the order of
15 to 30 minutes
in water at a very high temperature, typically 570 to 660 F. and pressure
100 to 170 atm
standard atmosphere, enough to keep the water in a liquid state to form oils
and residual solids);
b) indirect liquefaction (for instance, a two-step process to produce ultra-
low sulfur diesel by
first converting the biomass to a syngas, a gaseous mixture rich in hydrogen
and carbon
monoxide, followed by catalytically conversion to liquids, the production of
liquids is
accomplished using Fischer-Tropsch (FT) synthesis as applied to coal, natural
gas, and heavy
oils); c) integrated catalytic thermochemical process such as integrated
hydropyrolysis and
hydroconversion (IH2); d) hydroprocessing (the hydrothermal liquefaction (HTL)
of biomass
provides a direct pathway for liquid biocrude production via two types of
methods possible for
conversion of fatty acids to renewable diesel: "high-pressure liquefaction" or
"atmospheric
pressure fast pyrolysis").
[0044] Potable fresh water is produced as a byproduct of algal harvesting
system 116 that can be
recycled for other uses.
EXAMPLE
[0045] In this example, an algal core included a first algal growth component
that was a
heterotrophic component that included a heterotrophic algal strain and which
generated and fed
carbon dioxide to a second algal growth component was a photoautotrophic
counterpart that
included a photoautotrophic algal strain. It should be noted that the latter
could be a
photoautotrophic open pond/tank, or a hybrid system supporting
photoautotrophic or
mixotrophic growth.
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[0046] Two sets of bioreactors were setup to represent a test (an embodiment
of the algal core
discussed above) and a control. The control system was a closed
photobioreactor fed with
ambient air. The test algal core included two closed reactors, a heterotrophic
reactor and a
photoautotrophic reactor (supporting heterotrophic and photoautotrophic algal
growth,
respectively), where the photobioreactor was connected to ambient air supply
plus the additional
carbon dioxide generated from the heterotrophic reactor produced as a result
of fermentation
process. Both control and test systems were run in duplicate under the same
temperature
conditions, utilized artificially prepared media, and algae inoculums (also
referred to as algae
starter). In this experiment, when compared to the photoautotrophic
counterpart, only half of the
amount of algae starter was used in the heterotrophic reactor so as to
maintain control over the
heterotrophic reactor process.
[0047] For the heterotrophic reactor, additional glucose was added to the
artificial media, and the
reactor was run without exposure to light. The photobioreactors had the same
constant light
supply in both the test and the control batches. All reactors were regularly
monitored for optical
density, which indicates algal density (process discussed and shown in FIG.
6). Algal lipid
content was monitored at the end of the log phase (day 4) and thereafter via
confocal scanning
laser microscope¨a state-of-the-art multi-spectral imaging system using
lipophilic dye. It was
observed that the lipid content in the algal cells was negligible on day 4 and
was highest on day 7
making it reasonable to harvest biomass on day 7. It should be noted that
algae density can be
strain and inoculum specific as some algae cultures may surpass the log phase
earlier than 4
days, thereby making the harvest possible earlier than as shown in this
example.
[0048] FIG. 6 shows a chart 500 of algae density (as measured by optical
density) over time in
days. Line 504 represents the test reactors and line 508 represents the
control. As shown, very
little algal density exists prior to day 4. After day 4, however, optical
density substantially
increases for both systems; however, algal density of the test system outpaces
the control.
[0049] On the harvest day (day 7), the algal growth in the test algal core was
found to be about
1.37 times higher (i.e., 37% more) than in the control reactor, which is
considerable when
extrapolated. For example, a typical harvested photoautotrophic algae on dry
weight basis is in
the range of 300 mg/L (0.3 gm/L) to 1 gm or more in photobioreactors. Using
the more
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conservative harvest estimate, i.e., the 0.3 gm/L scenario, and extrapolating
to an exemplary and
typical 2000 ton/day algal growth system, a conventional photobioreactor
system (or open pond
system) would produce about 728,000 tons of algae biomass for oil extraction
annually, whereas
the photoautotrophic algal biomass harvest in the algal core, as discussed
above, would be about
994,728 tons-a 266,728 ton surplus harvest.
[0050] As noted above, the heterotrophic reactor received 50% of the algae
starter compared to
the photobioreactor; however, if both reactors included an equal amount of
algal inoculum the
amount of surplus algae from the heterotrophic reactor would be expected to
double due to
additional carbon dioxide generated by the heterotrophic reactor. If double
the amount of
heterotrophic algae was grown in the symbiotic system this would contribute a
surplus harvest of
3-4 times greater from the photobioreactor, thereby making the final surplus
outcome about two
or three times the harvest (i.e., about 74% to 111% more than the control).
This example also
illustrates how the volumes of the heterotrophic and photoautotrophic
components in the
symbiotic system could be customized to the algal harvest required from the
two respective
components. The surplus algal biomass generated could vary (lower or higher)
in some
embodiments depending on other factors such as media composition, light
exposure, algae strain
etc.
[0051] The examples and embodiments presented above could be applied to a
variety of seed
trains, where one system feeds a scaled up version of the system. Various
combinations of an
SAS, such as SAS 100, could be made with the other existing algal growth
systems and/or
microbial growth systems.
Looped Algae Reactor Design Pattern (LARDP)
[0052] SAS 100 can, in certain embodiments, include a Looped Algae Reactor
Design Pattern
(LARDP) 600, as shown in FIG. 7. LARDP 600 is a process and/or a system that
can be
added/attached to algal cultivating system 108, algal cores 156, 200, or 300,
or can be a
standalone system attached to a waste treatment, wastewater treatment,
remediation system for
cleaning wastewater/effluent streams using one or more strains of microalgae
(or other microbial
organisms such as bacteria, fungi etc.), or to any algae-based or microbial-
based process
producing a target product or byproducts. At a high level, LARDP 600 uses a
process of repeated
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cultivation of algae for co-product development and/or removal of nutrients
for improving water
quality of the effluent stream by growing algae biomass with or without other
microorganisms.
[0053] LARDP 600 can include a series of nutrient extraction systems (NES)
604, such as first
NES 604A and second NES 604B. Each NES 604 is designed to extract a certain
type or types of
components from an incoming effluent source 608, such as an algal effluent
stream from an algal
growth component, such as AGC 152A or 152B, or from other sources described
herein. In an
exemplary embodiment, first NES 604A includes a first algal stage 612 that
receives, as an
effluent stream as an input. First algal stage 612 is sized and configured to
use microorganisms,
such as those previously described herein, to extract from effluent stream 608
a certain type or
types of components, such as, but not limited to, a nitrogen, a phosphorus, a
heavy metal, a toxic
component, a particular element (e.g. Ca, K, Mg, Na, Al, Fe, Mn, B, Cu, Zn, S,
Pb, Cd, As), a
complex element such as an antioxidant (e.g. astaxanthin), and a nuclear
component. First, algal
stage 612 allows for the growth of the microorganisms and, in certain
embodiments, can be
similar in design to AGC 152B. At a desired time, the algal biomass produced
by first algal stage
612 is harvested at biomass processor 616, which can be performed as described
above. First
algal stage 612 also produces an effluent 620, which is at least partially
devoid of the component
that first algal stage 612 was designed to remove. This effluent can proceed
to one or more
primary pathways. The effluent can 1) be recirculated back to first algal
stage 612A for further
extraction of components (not shown), 2) proceed to a water recycling unit 624
for further water
treatment, 3) proceed to second algal stage 604B, and/or 4) return to algal
cultivating system 108
(FIG. 1) (when LARDP 600 is coupled to such a system). In general, the
concentration of the
dominating component in the effluent 620 determines its destination. For
example, if first algal
stage 612 contained predominantly the alga Chlorella vulgaris which removed
certain amount of
nitrogen and phosphorus such that effluent 620 contains almost no nitrogen but
still contained
phosphorus, the effluent would likely travel to the 612 system containing the
microorganisms
capable of utilizing phosphorus more efficiently than Chlorella vulgaris, such
as, but not limited
to Oscillatoria sp.
[0054] Second NES 604B and third NES 604C can be sized and configured to
remove the same
or a different type of component than that removed form first NES 604A. Second
NES 604B
thus can similarly include, a second algal stage 612B and a biomass processor
616B, and
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similarly third NES 604C can include, a third algal stage 612C and a biomass
processor 616C.
Additional stages 604 can be included to further extract components from
effluent streams and
recirculation to each stage in place in LARDP 600 can be performed. For
example, if at first
NES 604A, a first heavy metal is removed such that after entering the first
NES it is present in
the effluent stream in a lower concentration, the effluent can proceed to
second NES 604B where
another component, for example, a second heavy metal is removed to a lower
concentration. The
effluent from second NES 604B can then be recirculated to the first NES 604A
for further
removal of the first heavy metal, which is facilitated by the lower
concentration of the second
heavy metal.
[0055] In another exemplary embodiment, LARDP 600 is sized and configured to
produce
organic fertilizer from effluent steam 608. In this embodiment, at each NES
604 a desired
fertilizer component is removed, e.g., nitrogen, phosphorous, potassium, etc.
As each NES 604
allows for the harvesting of a concentrated amount of the desired component
that is entrained
within the organism, e.g., algae, in the NES, specific and fairly pure amounts
of the component
can be harvested and then mixed together to obtain the desired fertilizer
product.
[0056] In use, when attached to an algal system, such as algal culturing
system 108, microalgae
disposed within LARDP 600 is cultivated in the effluent generated by the algae
growth system.
In this embodiment, LARDP 600 is designed to remove undesirable substances
such as, but not
limited to, unwanted nutrients (e.g., nitrogen and phosphorus) and heavy
metals. The biomass
resulting from LARDP 600 can then be harvested from the wastewater and,
depending on what
LARDP has been designed to extract, processed to produce useful products such
as, but not
limited to, fertilizer and compost, or can be used as feedstock for digesters
producing energy
such as biogas or bio-electricity. After removal of the undesirable substances
as described above,
the remaining wastewater can then be further treated by cultivating the same
or a similar strain of
microalgae as used in algal growth system 108 for producing the primary
product, or the
remaining wastewater can be further treated by one or more different algae
strain(s) used as a
monoculture or a polyculture with or without other microorganisms such as
bacteria or fungi to
further remove nutrients (e.g., nitrogen and phosphorus) or heavy metals or
any other undesirable
components present in the wastewater generated. LARDP 600 can be repeated in
one or more
stages with same or different strains of algae and/or bacteria and/or fungi or
any other organisms
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compatible with algal strains, grown as a monoculture or polyculture in any
type of algal growth
system until the desired level of water quality is reached.
[0057] The number of NES 604s used in LARDP is determined by the number of
desired
removable elements in the effluent(s) that require capturing using microalgae
or microbes and
the desired water quality.
[0058] In an embodiment of the system, the one or more 604 stages in LARDP can
be optionally
combined or replaced by other processes such as multiple screening systems,
decanting
centrifugation, polymer flocculation, ammonia stripping, struvite formation,
nitrification/de-
nitrification, etc. Modifications of these processes can also be used for
enhancing the whole
process of nutrient removal.
[0059] LARDP 600 can be useful in the creation of products, including, but not
limited, to
biofuels, fertilizer, animal feed, and cosmetics. The organisms cultivated in
LARDP 600 can be
cultivated under a green house or other similarly enclosed environment, so as
to prevent
contamination by competitive microorganisms while admitting light. LARDP 600
can be
implemented in, for example, vertical freestanding tanks, raceway style ponds,
or tracks.
[0060] Additional useful byproducts from SAS 100 include the production of
clean carbon
dioxide (as compared to the CO2 captured from flue gases) generated from an
algal growth
component, such as AGC 152A, which, while discussed previously as supporting
AGC 152B,
can also be captured and used for other applications needed a clean source of
CO2, e.g., medical
applications, electronics, laboratories, etc. Alternatively, the CO2 can be
used for algal
inoculum-preparation (a highly concentrated algae culture typically used for
seeding a larger
scale system) especially to generate light-dependent inoculum for seeding a
system or sub-
system.
[0061] FIG. 8 shows a process 700 for removing contaminants from a waste or
effluent stream.
At step 704, the content of the waste or effluent stream is determined. While
typical nutrients,
such as nitrogen and phosphorous are likely to be found, the stream may also
include heavy
metals or other nutrients that are desirably removed from the stream before
the stream is put to
further use or otherwise treated. Determining which nutrients and other
particles are a part of the
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waste or effluent stream will assist in determining the type of nutrient
extraction system, such as
one of the NES 504s discussed above, to implement.
[0062] At step 708 it is determined whether any preprocessing is necessary
prior to the stream
entering the first NES. Preprocessing may be necessary if the stream contains
significant solids
or too much liquid. If preprocessing is necessary, process 700 proceeds to
step 712 where a
suitable preprocessing system is developed. Exemplary preprocessing systems
are solids
treatment unit 140 and separator 136 as discussed above with reference to FIG.
1. If no
preprocessing is necessary, process 700 proceeds to step 716.
[0063] At step 716, a first NES is used to extract components from the waste
or effluent stream.
In an exemplary embodiment, first NES is sized and configured to focus on a
relatively small
number of components for extraction. For example, if the input waste or
effluent stream is
nitrogen rich, first NES may be configured to include an algal component that
is primarily
effective at removing a substantial portion of the nitrogen from the waste or
effluent stream. The
output of first NES is then provided to a second NES at step 720 for
extraction of another
component of the original waste or effluent stream.
[0064] At optional step 724, a determination is made as to whether further
removal of nutrients
from the output of step 720 is desired. As part of step 724, a determination
of the composition of
the output of step 720 may be completed and may be used when the effectiveness
of steps 716
and 720 and may be necessary so as to determine where, if anywhere, the output
of step 720
should be sent. For example, in order to effectively remove a heavy metal from
a waste stream, it
is generally beneficial to remove nutrients that are in the stream in
significant amounts.
Therefore, if, for example, the output of step 720 included significant
amounts of a nutrient, e.g.,
nitrogen, which would render extraction of the heavy metal difficult or
inefficient, step 724
would determine that the stream should be sent to an NES that will efficiently
remove more
nitrogen (e.g., step 716). However, if removal of a different component is
desired, process 700
may proceed to step 728 where a third NES is used to extract components form
the output
stream. If no further extractions are necessary, the process ends.
[0065] Turning now to a discussion of FIG. 9, there is shown energy return
values (EROI) for
biodiesel by feedstock. The EROI is calculated as the ratio between the energy
produced and the
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energy consumed by a system, and is generally considered a critical measure
for evaluating the
net energetic profitability of that system. As the EROI increases, the
energetic profitability of
that energy system also increases. For any feedstock (e.g., algae, soybean
oil, etc.) or
combination of feedstocks (e.g., SAS 100) to be a net energy source, the EROI
to operate the
entire associated production system(s) must be greater than 1. However,
historically, the EROI of
viable energy sources has been much greater than 1 and, therefore, practical
deployment of an
energy source typically requires an EROI much greater than 1. For instance,
the EROI has been
used to characterize several conventional fuels; for example, for coal, oil
and gas, and corn
ethanol, the second-order EROI has been estimated to be -80 (at the mine), -15
(at the well), and
-1 (at the biorefinery). Delivered gasoline (considering the entire supply
chain) has reported an
overall EROI of around 5 to 10.
[0066] As shown in FIG. 9, the EROI range is a low of 0.76 for sunflower oil
to a high of about
5.88 for reclaimed vegetable oil. In comparison, certain embodiments of SAS
100 (varying
pretreatment and algae types) obtained an energy return values of about 1, 11,
and 40. Under
certain conditions it can go even higher.
[0067] Turning now to FIG. 10, there is shown another exemplary symbiotic
algae system, SAS
800, according to an embodiment of the present disclosure. At a high level,
SAS 800 is similar in
many respects to SAS 400, and as such, unchanged/substantially similar
components have been
numbered according to SAS 400. SAS 800 includes, but is not limited to,
acquiring of feedstock
inputs 404 from, for example, stakeholders, pretreater 408, solids separator
804, algae cultivator
412, biomass harvester 416, oil extractor 420, byproducts manufacturer 424,
and recycling of
materials 428. Feedstock inputs 404 may be from a variety of stakeholders
external to the SAS
400 operators, such as dairy manure waste generated at a farm (or in case of
an industrial
process, such as brewery, its generated wastes). Feedstock inputs 404 are
processed through
pretreater 408, which can be an anaerobic digester that in addition to
generating effluent useful
for algae cultivation, and also generate biogas and/or bio-electricity as
alternative energy.
Pretreater 408 is capable of generating an effluent/wastewater stream 806 with
reduced odor and
biochemical oxygen demand (BOD), which is advantageous for water quality.
However,
typically the pretreatment process of pretreater 408 does not remove nitrogen
and phosphorus,
which is a significant environmental issue, and due to government regulations
typically requires
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further treatment for its safe discharge into natural water bodies. SAS 400
recovers the nutrients
from effluent/wastewater via algae cultivator 412, which can be, for example,
an embodiment of
algal growth system 108 as described herein or as a standalone growth system
or as a
combination of an algal growth system supporting photoautotrophic,
mixotrophic, or
heterotrophic mode of production of algae utilizing appropriate algae strains.
[0068] At a desired time, the algal biomass produced by algae cultivator 412
is harvested at
biomass harvester 416, which outputs lipids, water, and solids¨each of which
can be a useful
produce or recycled within SAS 400. For example, lipids are extracted at oil
extractor 420; water
can be recycled into one or more of the other processes within SAS 400 such as
algae cultivator
412 or back to one of the stakeholders (such as a dairy farm); and solids can
be converted into
animal feeds or fertilizers. The post-harvest algal biomass (also referred to
as algae cake), and/or
other algal biomass is utilized for production of additional useful
byproducts, such as fertilizer or
animal feed depending on the throughput feedstock used. For example, algae
biomass grown
with dairy manure waste would be more appropriate as a fertilizer instead of
animal feed due to
required FDA compliance. In contrast, brewery effluent, which is a cleaner
byproduct of beer
processing and typically being food grade, can be used for producing algal
biomass for high
value animal feed. The crude oil extracted by oil extractor 420 goes through
further processing to
obtain desirable end products (biodiesel, oil-heat, jet fuel), and is then
stored, transported and
used in vehicles, planes or for heating purposes. Notably, as algae is a CO2
sink, one can expect
that at least a portion of the CO2 generated by the local use of the
aforementioned products can
be recaptured by the algal biomass production process along with the CO2 from
the farm
operations. Heat captured by pretreater 408 or from other onsite operations
can be used as a heat
input for algae cultivator 412, biomass harvester 416, oil extractor 420,
and/or for sterilizing the
algae cake that is used for animal feed production. Solid separator 804
separates the solids
produced by pretreater 408 and can be used for production of fertilizer or
soil mixes or soil
amendments for plant growth described below in the exemplary compositions.
Solid separator
804 can include a drying component (not shown). Solids separating can be
accomplished by
screening, using a centrifuge, or via other technologies known in the art.
[0069] Certain compositions discussed herein use digestate solids (which is a
byproduct of
anaerobic digestors that contains things, such as, fibrous undigested organic
material made of
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lignin and cellulose, some microbial biomass, animal hair, and nitrogen,
phosphorus and other
nutrients) produced by most any type of anaerobic digestor such as, but not
limited to, covered
storage, plug flow digester, mixed plug flow digester, complete mix digester,
fixed film digester,
induced blanket digester, two- stage digester etc. Notably, the digestate
solids are almost
pathogen free.
[0070] In an embodiment, SAS 800 can include enhanced biological phosphorus
removal system
808 that uses the naturally occurring microorganisms present in the waste
stream. Removal
system 808 may consist of alternating anaerobic (absence of oxygen) and
aerobic conditions. In
this situation, in the anaerobic phase, phosphorus accumulating organisms
(PAOs) are used for
the biological processing of slurry/sludge/effluent obtained through for
example, anaerobic
digestion. In operation, the PAOs consume the volatile fatty acids, such as
acetate, in the
slurry/sludge/effluent, which is further converted into poly-fl-
hydroxyalanoates (PHA). In the
follow up aerobic phase the PAOs grow and consume more phosphorus as a result
of
accumulation of polyphosphate within their cells. This predominantly bacterial
biomass is
separated through one or more processes of solid concentration and separation
described herein
(e.g., via solids separator 804). The separated biomass can, as explained
elsewhere herein be
pretreated for removal of the effect of pathogens, moisture content and/or pH
adjusted and used
as a component of fertilizer or soil mix composition. In certain embodiments
removal system
808 can be an add on feature to an SAS or in some situations can replace
solids separator 804.
[0071] Notably, PAOs and algae (photoautotrophic, and/or mixotrophic and/or
heterotrophic)
can be grown together in anaerobic and/or aerobic phases described above with
the appropriate
algae strains.
[0072] Removal system 808 can include flocculation, where polymer or coagulant
chemicals or
binders are added including one or more of organic polymers, inorganic
polymers ¨
polyacrylamides, chemicals, FeCl2, FeSO4, A1SO4 etc.
[0073] In an embodiment of removal system 808, the enhanced biological
phosphorus removal
system is followed by struvite crystallization for maximizing the nutrient
recovery (discussed
further below with respect to FIG. 12, below). Generally, after solids
separation, the
slurry/sludge/effluent is treated with chemicals including magnesium chloride
in an amount
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sufficient to combine with ammonia and phosphorus in an approximately in a
mole to mole to
mole ratio (1:1:1) of magnesium, ammonia and phosphate so as to crystallize as
Magnesium-
Ammonium-Phosphate (MAP) or struvite (MgNH4PO4.6H20), which is then separated
and
washed.
[0074] Turning to FIG. 11, there is shown another exemplary SAS, SAS 900,
which, in contrast
to other SAS systems discussed herein, receives nutrients from a slurry
collection system 904.
Slurry collection system 904 can be an open or a closed structure or container
to contain the
waste slurry or sludge that optionally facilitates aeration and/or
recirculation and/or flocculation
of slurry/sludge.
[0075] Additionally, SAS 900 can receive one or all of the nutrients from the
effluent generated
by an additional nutrient recovery process 908 that treats the slurry from
slurry collection system
904 so as to recover nutrients such as phosphorus and/or nitrogen in a range
from about 0.5% to
about 99% depending on the concentration of nutrients in the slurry/sludge or
effluent processed
through a solids separator 912, which in this exemplary embodiment includes a
processing
centrifuge 916 and a screw press composter 920 to produce a separator solids
cake and a
separated solids, respectively. The pH of the slurry/sludge or effluent is
optionally adjusted by
the use of acidic or basic additives.
[0076] Screw press composter 920 generates the two streams ¨ a liquid and a
solid. The solid
portion goes through further processing through a composter (not shown) such
as drum
composter, and the solids are separated. The liquid portion goes through a
solid concentration or
separation process through screening and/or an equipment such as a centrifuge
to separate the
solids with higher concentration of nitrogen and or phosphorus compared to the
first iteration of
solid separation through an equipment such as a screw press. In an exemplary
process processing
centrifuge 916 directly receives inputs from slurry collection system 904. The
effluent generated
become additional feed stock inputs 404. The digestate solids and/or the
separated solid cake
produced slurry collection system 904 are optionally processed or sterilized
to make a pathogen
free material usable for production of fertilizer or soil mixes or soil
amendments for plant growth
described below in the exemplary compositions.
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[0077] Turning now to FIG. 12, which shows a SAS 1000 including a removal
system 1004 that
includes struvite crystallization 1008. In operation, the pH is adjusted to
form the MAP crystals.
Crystallized struvite appears is sparingly soluble in neutral and alkaline
conditions, but readily
soluble in acid. MAP is used as one of the components of fertilizer or the
soil mixes described
below. In some cases, depending on the types of slurry/sludge and/or effluent
(such as dairy
manure containing calcium-phosphate), precipitates are run through acidic
pretreatment for
releasing the phosphorus contained in the precipitates, which is then treated
with magnesium
chloride that crystallizes as MAP (as discussed above). The acid pretreatment
of calcium to
release phosphorus can optionally involve lowering pH or addition of acids.
One of the benefits
of separating MAP prior to feeding the nutrients to a biomass system, such as
a SAS, is that it
reduces the inefficiency within the biomass/algal growth and harvest system
because of clogging
of the plumbing, pipes, pumps and other equipment caused by excessive
phosphorous. Another
benefit of the recovered struvite or the crystallized phosphorus is that it
can be mixed with algae
and/or separated solids and/or other components to make fertilizer or soil
mixes. For example,
standalone struvite fertilizer has a low nitrogen, high phosphorus N-P-K
value, e.g., 6:29:0.
However, issues with using standalone struvite as fertilizer can include an
increase in soil pH
level that may affect the nutrient uptake by plants and plants cannot intake
all of the magnesium
component. In contrast, combining struvite with biomass based fertilizer and
adding additives to
balance N-P-K and/or pH makes the nutrients better available for plants.
[0078] In another embodiment, and as shown in FIG. 13, a SAS 1100 includes a
removal system
1104 that has a dissolved air flotation (DAF) system 1108 that is downstream
of a solids
separator 1112. In this embodiment of DAF system 1108, compressed air is
passed through water
to form bubbles from dissolved air, and then mixed with the screened
slurry/sludge/effluent so
that the bubbles adhere to the suspended solids to push those to the surface,
where they are
separated through flocculation. Typically, pH adjustment is then done.
Pretreatment through the
use of flocculants (described earlier) is done to improve the suspended solids
removal. The
solids, containing elements such as phosphorus, are separated through
mechanical means such as
an auger screw press, filter press, belt filter press, centrifuge etc. The
effluent generated is fed to
a SAS, such as SAS 400. The separated solids can be used as a component in the
fertilizer or soil
mixes. In certain embodiments of SAS 1100, an ammonia-stripper may be used to
adjust pH and
temperature before water is passed through it for stripping ammonia.
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[0079] In another embodiment, and as shown in FIG. 15 there is shown another
embodiment of a
symbiotic algae system, SAS 1200, which, in contrast to other SAS systems
discussed herein,
receives nutrients from a solid separation system 1204. Solid separation
system 1204 can be an
anaerobic system, such as an anaerobic digester, or any other solids
separator, such as, but not
limited to, a settling tank, a centrifugal separator, and a screw press
separator. The solid
separation system 1204 can separate solids from liquid, and/or promote
dehydration so as to
provide the recovered solids to thermal decomposition system 1208, which can
be, for example,
a torrefaction system (heating from between about 225 C and 300 C), a
pyrolysis system
(heating from between about 300 C and 650 C), a gasification system (heating
from between
about 700 C and 850 C), or a combustion system (e.g., an incinerator), whereby
the solids are
exposed to high temperatures to promote decomposition. The aforementioned
systems can
generally include a feed intake, and a reactor, such as a gasifier or
fluidized bed reactor or other
reactor systems known in the art. In an embodiment, thermal decomposition
system 1208 heats
the recovered solids in the presence of little or no oxygen and produces by-
products, such as
biochar, bio-oil (also referred to in the industry as bio-crude), and gases.
[0080] Biochar can be processed to make a material usable for production of
fertilizer or soil
mixes or soil amendments for plant growth described below in the exemplary
compositions. The
bio-oil is optionally used for biofuel production. The gaseous components (as
a result of
dehydration, devolatilization, or gasification) can be used as a fuel for heat
required elsewhere in
the system, and the CO2 gases can be used as a feedstock for algal biomass.
[0081] In an embodiment, solid separation system 1204 can include a harvesting
unit. For
instance, a solid separation system 1204 can be installed, with or without a
dual-stage algal
growth system, at a farm that has nutrient runoff collection pits which
naturally produce algae
and microbes. A solid separation system 1204 can harvest these algae and/or
microbes from the
runoff collection structures, dehydrate and add them to the separated solids,
and/or biochar to
produce valued products such as fertilizer, soil mix, soil enhancements, etc.
Algae cake with or
without the addition of wild or naturally occurring algae can be dried or
mixed with additional
biomass for conversion into the aforementioned types of products. In some of
the instances of
solid separation system 1204, the algae cake is densified by the addition of a
secondary material
or a mix of organic materials such as, but not limited to, sawdust, hay,
grasses, or waste or
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surplus from various wood related processes, including, but not limited to,
wood milling,
pelletization, or puck creation. The effluent from solid separation system
1204 can be optionally
fed to a standalone algae growth system utilizing any type of algae: a
photoautotrophic, or
mixotrophic or heterotrophic.
[0082] Any of the systems described herein can include filtration and/or
disinfection systems
Screening can be sequential, mechanical, chemical or both, so as to separate
the solids that can
interfere in the biomass growing process. Disinfection of nutrient containing
effluent or aqueous
material used for biomass growth or the biomass itself can be completed using
steam and/or
chemical treatment and/or ultraviolet treatment to make the biomass pathogen
free. Exemplary
algal strains include, but are not limited to, Chlorella vulgaris, Chlorella
pyrenoidosa, Spirulina
platensis, Haematococcus pluvialis, Athrospira sp. Scenedesmus sp., and other
algae strains such
as Dunalliella rich in Highly Unsaturated Fatty Acids for aquaculture.
[0083] The disclosed composition(s) below can be used as nutrients or
fertilizers or soil mixes
for plant growth in farming operations, in open or closed or partially covered
crop fields,
greenhouses, hoop houses, or low tunnel based plant growth operations, private
gardens, yards,
floriculture, aquaponics, or hydroponics. Some of the compositions enhance
soil aeration and
provide peat-moss amendments with high water retention capabilities.
EXEMPLARY VALUED PRODUCTS
[0084] Some of the compositions are 'organic' and/or `biobased' and/or
`biopreferred' where
compositions of N-P-K provide 75% (or above) organic carbon-based nutrition
for plant growth.
Some of these compositions contain one or more components from the waste grown
biomass,
and/or one of more byproducts of processes described herein, such as separated
solids,
phosphorus cake or crystals etc. and/or the additives described herein. The
composition is pH
balanced.
[0085] An exemplary embodiment of a composition for plant growth and/or soil
fertility is
comprised of dry weight N-P-K percentages of around 1.42-1.40-1.37,
respectively (equivalent
to N-P-K 1-1-1 percentages). The disclosed exemplary composition is made from:
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a) predominantly suspended microalgae biomass grown with the liquid effluent
from
anaerobically digested manure and/or co-digested with food waste;
b) ash and/or biochar from organic source ¨ a byproduct of burning wood;
c) digestate solids produced as byproducts of co-digestion; and
d) pH adjustment using an additive.
[0086] Another exemplary composition comprises 1.97-1.86-1.3 N-P-K percentages
equivalent
to 2-2-1. The composition is made from:
a) predominantly suspended microalgae biomass grown with the liquid
effluent from
anaerobically digested manure and/or co-digested with food waste;
b) Ash and/or biochar from organic source ¨ a byproduct of burning wood; and
c) pH adjustment using an additive.
[0087] An exemplary composition suitable as a potting mix capable of retaining
moisture
between 1.5 to 5 times its dry weight includes N-P-K about 0.85-0.40-0.12
having a 5:95
composition of:
a) predominantly biomass (e.g. suspended microalgae) grown with the liquid
effluent from
anaerobically digested manure and/or co-digested with food waste, and/or
effluent from
solid separation and/or pretreatment;
b) separated solids produced; and
c) pH adjustment using an additive.
[0088] An exemplary composition suitable for use as a potting mix contains a
combination of:
a) predominantly suspended microalgae 1 biomass grown with the liquid effluent
from
anaerobically digested manure and/or co-digested with food waste;
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b) separated solids produced as byproducts of digested manure and/or co-
digested with <5%
food waste;
c) Peat moss, coir, vermiculite to reduce the existing use of peat moss, and
vermiculite
without depriving the soils of benefits from these, whereas provide an
alternative to
reduced use of peat moss and vermiculite; and
d) pH adjustment.
[0089] Another exemplary composition of fertilizer mix contains enriched
nitrogen content and
is formed from:
a) Biomass (e.g. predominantly suspended microalgae) grown with the liquid
effluent from
anaerobically digested manure and/or co-digested with food waste;
b) nutrient enhancement material(s) that may be a byproduct of a process
and/or a fertilizer
available, such as, but not limited to one or more of: Ammonium Nitrate
(NH4NO3)
[grade: 37-0-0, composition: 18.5% N-NO3 (Nitrate nitrogen), 18.5% N-NH4
(Ammonium nitrogen) ]; Ammonium Sulfate ((NH4)2504) [grade: 21-0-0,
composition:
21% N-NH4, (Ammonium Nitrogen) 73% 504 (sulfate)]; Ammonium Sulfate Nitrate
(H12N4075) [Grade: 26-0-0, composition: 19% N-NH4 (Ammonium nitrogen), 7% N-
NO3 (Nitrate nitrogen), 14.5% S-504 (Sulfate)]; Calcium Ammonium Nitrate
(5Ca(NO3)2-NH4NO3*10H20) [grade: 15.5-0-0, composition: 14.4% N-NO3, 1.1% N-
NH4, 19% Ca]; Magnesium Nitrate (Mg(NO3)2) [grade: 11-0-0 0-9.6; composition:
11%
N-NO3, 9.6% Mg]; Magnesium Sulfate (Mg504) [grade: 0-0-0 - 0-9.1; composition:
9.1% Mg, 14% S (42% 504)]; Mono Ammonium Phosphate (MAP) (NH4H2PO4)
[grade: 12-61-0, composition: 12% N-NH4, 26.5% P (61% P205)]; Mono Potassium
Phosphate (MKP) (KH2PO4) [grade: 0-52-34, composition: 22.5% P (52% P205), 28%
K (34% K20)]; Potassium Nitrate (KNO3) [grade: 13-0-46, composition: 13% N-
NO3,
38% K (46% K20)]; Potassium Sulfate (K2504) [grade: 0-0-52, composition: 43% K
(52% K20), 18% S (54% 504)]; Urea C0(NH2)2 [grade: 46-0-0, composition: 46% N-
NH2]; Potassium Chloride (KC1) [grade: 0-0-60, composition: 50% K (61% K20)];
Copper Sulfate (CuSO4*5H20) [ composition: 25% Cu, 13% S]; Zinc Sulfate
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(ZnSO4*7H20) [composition: 22% Zn, 11% S]. In an instance of bio-preferred
composition includes the standard allowed limit such as at least 75% organic
material and
the amount of enhancement nutrient is added accordingly; and
c) Additives and/or pH adjustment and/or organic solids.
[0090] An exemplary composition of fertilizer contains a combination of:
a) predominantly suspended microalgae biomass grown with the liquid effluent
from
anaerobically digested manure and/or co-digested with <5% food waste Separated
solids
produced as byproducts of livestock manure or co-digestion;
b) struvite; and
c) pH adjustment.
[0091] The fertilizer compositions described above can be a slow release
fertilizer (also known
as controlled release or extended release), in which the composition includes
the slow release
enhancing ingredients and/or coating on the granules. Alternatively, a
"reactive layer coating"
can be made by applying reactive monomers to the soluble grains or particles
of the fertilizer.
[0092] In an exemplary embodiment, the biomass produced by the SAS' described
herein is
from the aquatic species suitable for growing animal feed or for
nutraceuticals. For example:
a) 15% Predominantly Spirulina platensis biomass (over 50% crude protein
content) grown
using the strain with the pretreated liquid effluent from anaerobically
digested manure
and/or co-digested with <5% food waste;
b) 85% ordinary daily ration including grains/meal (from soybean, corn etc.
for high energy
and starch content), hay forages, alfalfa etc; and
c) Supplements.
ADDITIONAL EXAMPLES
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[0093] The following examples are provided to illustrate certain embodiments
and are not to be
construed as limitations on the embodiments, as set forth in the claims. All
parts and percentages
are by weight unless otherwise specified.
Example 1
[0094] An organic and/or biobased and/or biopreferred fertilizer composition
with a moisture
content 4% or less comprised of following:
a) over 75% predominantly algal biomass grown with the liquid effluent from
anaerobically
co-digested manure with <5% food waste;
b) ash for enhancing potassium concentration;
c) soybean meal for enhancing nitrogen content; and
d) pH adjustment via an additive option.
Example 2
[0095] A set of tests were conducted to determine growth of vegetable
(lettuce) in a controlled
greenhouse environment. The market brand soil mix was used that contained 75-
85% Sphagnum
peat moss, perlite (horticultural grade), vermiculite (horticultural grade),
dolomite and calcitic
limestone (pH adjuster), wetting agent, mycorrhizae ¨ endomycorrhizal fungi
(Glomus
intraradices) as one active propagule per gram of growing medium. The 25%, 50%
and 100%
fertilizer composition was mixed with the soil mix in the respective batches
of trials. All the pots
were watered with measured amounts of water sufficient to retain the moisture
and not flow out.
The control had no fertilizer. In each pot 5 seeds of lettuce were sown. After
the seedling
germinated and first leaves emerged, the plants were thinned to two plants.
[0096] As shown in FIG. 14:
a) FIG. 14A: control with no added fertilizer;
b) FIG. 14B: 25% fertilizer composition;
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c) FIG. 14C: 50% fertilizer composition; and
d) FIG. 14D: 100% fertilizer composition.
[0097] There was a significant effect of fertilizer composition on the shoot
biomass. All the three
compositions resulted in increases in shoot growth, with the highest being the
100%
composition.
Example 3
[0098] A slow release composition of algal-based fertilizer described in
example 1 was used for
preparing a new composition by the addition of biochar. Two experiments were
conducted by
mixing 0%, 10%, 20% and 30% of the algal-base fertilizers with soil media. The
first experiment
included the fertilizer composition containing biochar whereas the second
experiment did not
include biochar. The results indicated the 10% fertilizer treatment performed
the best for
germination of seeds in both the trials.
Example 4
[0099] A set of tests were conducted to determine vegetable growth (lettuce)
in a controlled
greenhouse environment. The market brand potting soil mix, Magic Dirt, made by
Magic Dirt,
LLC of Little Rock, Arkansas, was used. Magic Dirt claims to have a base
component been
derived from anaerobically digested manure and food waste and claims to
include aged forest
products. Magic Dirt claims to have a nitrogen-phosphorus-potassium (N-P-K)
composition of
1.15%, 0.30%, and 0.35%, respectively. According to US Patent No. 9382166,
which is owned
by Magic Dirt LLC and discloses the same N-P-K composition, the composition
can be
stabilized for a pH between 6.0 to 7.0 by adding pine bark composted for a
duration in the range
between about 9 months to 12 months. The composition included typically 75%
digested solids
material mixed with composted 25% pine bark. Magic Dirt's Organic Potting Soil
used in the
tests claims to produce plant growth the same as many other brands of soil
mixes.
[0100] The first test algae-based soil mix had an N-P-K composition of 1.46%,
1.17%, and
0.95%, respectively. The base component of the test-algae soil mix was derived
from
anaerobically digested manure and food waste, and the base was stabilized for
pH by adding
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algae biomass. The soil mix comprised 75% digested manure solids and 25% algae
biomass. A
side by side trial of plant growth was conducted under the temperature and
light conditions as
described below.
[0101] In addition to the comparative test described above, a second test
algae-based soil mix
was prepared that had an N-P-K composition of 1.46%, 1.17%, and 0.95%,
respectively. The
base component of the test-algae soil mix was derived from anaerobically
digested manure and
food waste, and the base was stabilized for pH by adding algae biomass. The
soil mix comprised
75% digested manure solids and 25% algae biomass. In contrast to the first
test algae-based soil
mix, the base component was rinsed with freshwater before mixing the algae
biomass for
creating the soil mix.
[0102] All the pots were watered with measured amounts of water sufficient to
retain the
moisture and not flow out. In each pot 5 seeds of lettuce were sown. After the
seedling
germinated and first leaves emerged, the plants were thinned to three plants.
[0103] With reference to FIGS. 16A-C, which show different stages of the
lettuce growth during
tests 1300, all the three soil mix compositions, i.e., the Magic Dirt
(hereinafter, "Mix A"), the
first test algae-based soil mix (hereinafter "Mix B"), and the second test
algae-based soil mix
(hereinafter "Mix C") resulted in increases in plant growth. However, there
was a significant
effect of Mix B and Mix C on the plant growth compared to Mix 1. Specifically,
and with
reference to the first three stages of lettuce growth ¨ in the "seed
germination" stage, when the
first set of leaves (called "seed leaves") emerge from the seed. As shown in
FIG. 16A, at a first
time 1304, all three mixes (labeled as A, B, and C in FIG. 16A) showed
emergence of first set of
leaves. In the second stage, the "seedling stage", where the lettuce plants
develop first true
leaves, at a second time 1308 (shown in FIG. 16B) Mix B and Mix C showed
emergence of true
leaves and the rosette pattern typical of lettuce plant. However, Mix 1 did
not transition into the
seedling stage, but remained in the seed germination stage. In the third
stage, the "head
development" stage, where leaves start to form a cup shape and develop into
its head, both
Mix B and Mix C started showing signs of early cup and head formation, whereas
Mix 1
remained in the germination stage. At time 1312 (shown in FIG. 16C), Mix 1
started showing
the signs of entering into the seedling stage (highlighted with a circle
1316), whereas both Mix B
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and Mix C progressed further with plant growth with larger leaves. The fourth
stage is the
"flowering and leaf development" stage. Usually lettuce is harvested before
the fourth stage and
thus the test was ended. As is evident, both Mix 2 and Mix 3 produced more
robust plant growth
that Mix 1.
[0104] FIG. 17 shows an exemplary growth structure 1400 for use with an algae
growth system
as described herein. In this embodiment, growth structure 1400 includes a
plurality of raised
canals 1404, a covering 1408, an aeration component 1412, and a canal cover
1416. Each canal
can be a three-sided container that has sides made of light-penetrating
materials to allow for
certain types of algal growth. As shown, canals 1404 are located inside a
covering 1408 that is
also made from light-penetrating materials. Light-penetrating materials can
be, but is not limited
to, plastic, polyethylene, polystyrene, acrylic, acetal, and fiberglass. In
alternative embodiments,
each canal can be either entirely or partially covered by canal cover 1416,
which is also typically
made from light-penetrating materials. Overall, growth structure 1400 can be a
small as a few
square feet to as large as 100,000 acres. Each canal 1404 can be as long and
wide and high as
desired. Although three canals are shown in FIG. 17, the number of canals may
vary as desired.
[0105] In an exemplary aspect, a symbiotic algae system is disclosed that
comprises: a first algal
growth component, wherein the first algal growth component includes a
heterotrophic organism,
and wherein the first algal growth component produces a first effluent and an
off-gas; and a
second algal growth component is fluidly coupled to the first algal growth
component, and the
second algal growth component including at least one organism from the group
of: a
photoautotrophic organism, a mixotrophic organism, and a heterotrophic
organism, and wherein
the second algal growth component receives, as an input, the first effluent
and the off-gas and
produces a second effluent. In the symbiotic algae system, the first algal
growth component can
receive, as a first input, an effluent input or a waste input. In the
symbiotic algae system, the
second algal growth component can receive, as a second input, an effluent
input or a waste input.
The symbiotic algae system can further include a waste nutrient preparation
sub-system fluidly
coupled to the first algal growth component. In the symbiotic algae system,
the waste nutrient
preparation sub-system can receive an effluent input, a fresh water input, and
waste input, and
outputs an effluent suitable for use by the first algal growth component. In
the symbiotic algae
system, the waste nutrient preparation sub-system is a manure settling and
solid's preparation
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unit that outputs liquid manure waste to the first algal growth component. The
symbiotic algae
system can further include an algal harvesting system having at least one
separator, wherein the
algal harvesting system is fluidly coupled to the first algal growth component
and/or the second
algal growth component. The symbiotic algae system can have an EROI greater
than 10. The
symbiotic algae system can have an EROI of about 40. The symbiotic algae
system can further
comprise a third algal growth component, wherein the third algal growth
component includes at
least one organism from the group of: a photoautotrophic organism, a
mixotrophic organism, and
a heterotrophic organism, and wherein the third algal growth component
receives, as an input,
the second effluent. The symbiotic algae system can further comprise at least
one biomass
processing unit, the biomass processing unit sized and configured to extract
lipids from at least
one of the first algal growth component and the second algal growth component.
[0106] In another exemplary aspect, a symbiotic algae system is disclosed that
comprises a first
algal growth component, wherein the first algal growth component includes a
heterotrophic
organism, and wherein the first algal growth component produces an first
effluent and an off-gas;
and a second algal growth component fluidly coupled to the first algal growth
component,
wherein the second algal growth component includes at least one organism from
the group of: a
photoautotrophic organism, a mixotrophic organism, and a heterotrophic
organism, and wherein
the second algal growth component receives, as a first input, the first
effluent and the first off-gas
and produces an second effluent and a second off-gas; and wherein the second
effluent and the
second off-gas are received as inputs to the first algal growth component. In
the symbiotic algae
system, the first algal growth component can receive, as an additional input,
an effluent input or
a waste input, and wherein the additional input and the second effluent
include a nitrogen and a
phosphorous. In the symbiotic algae system, the first algal component can
remove a portion of
the nitrogen and the phosphorous from the second input and the additional
input. The symbiotic
algae system can further comprise a third algal growth component, wherein the
third algal
growth component includes at least one organism from the group of: a
photoautotrophic
organism, a mixotrophic organism, and a heterotrophic organism, and wherein
the third algal
growth component receives a portion of the second effluent. The symbiotic
algae system can
further comprise at least one biomass processing unit, the biomass processing
unit sized and
configured to extract lipid/oil from at least one of the first algal growth
component and the
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second algal growth component. The symbiotic algae system can have an EROI
greater than 10.
The symbiotic algae system can have an EROI of about 40.
[0107] In yet another exemplary aspect, a symbiotic algae system can comprise:
a waste nutrient
preparation sub-system; an algal culturing system including: a first algal
growth component
fluidly coupled to said waste-nutrient preparation sub-system, wherein the
first algal growth
component includes a heterotrophic organism, and wherein the first algal
growth component
produces a first effluent and an off-gas; and a second algal growth component,
wherein the
second algal growth component includes at least one organism from the group
of: a
photoautotrophic organism, a mixotrophic organism, and a heterotrophic
organism, and wherein
the second algal growth component receives, as an input, the effluent and the
off-gas and
produces a second effluent; and an algal harvesting system fluidly coupled to
said algal culturing
system; an algal biomass processing system fluidly coupled to said algal
harvesting system; and
a byproducts system fluidly coupled to said algal biomass processing system.
In the symbiotic
algae system, the waste nutrient preparation sub-system can receive, as an
input, an effluent
input or a waste input.
[0108] Additives for composition adjustment and/or enhancement and/or pH
control/adjustment
by using one or more or a combination of following: granular, hydrated,
pelletized, pulverized,
solid, liquid, gel, emulsion, dispersion, suspended, dissolved, water soluble,
water insoluble,
powder, byproducts or other forms of following, but not limited to: limestone
or lime (such as
calcitic limestone - mostly calcium carbonate, and dolomitic limestone to
mostly add
magnesium); potash such as potassium chloride, potassium sulfate, potassium
carbonate,
or potassium nitrate etc.; wood ash; ash from other sources, such as plants,
ligno-cellulosic
material; lignoSulphonate oils; biochar; coal, sulfur; sulphates, carbonates;
phosphates (may be
one or more of organophosphate, an ester of phosphoric acid, and/or inorganic
chemical(s) and
a salt-forming anion of phosphoric acid); orthophosphate and polyphosphate,
pyrophosphate,
hydrogen phosphates; dihydrogen phosphates; rock phosphate, treated or
untreated fluorapatite
Ca5(PO4)3F (CFA) and/or hydroxyapatite Ca5(PO4)30H; organic and inorganic
forms of nitrogen
(such as soybean or cottonseed meal), nitrogen fertilizer (nitrogen as urea,
ammonium, nitrate or
a mix); liquid nitrogen, calcium nitrate, anhydrous ammonia, ammonia, ammonium
nitrate;
straight fertilizers; struvite (magnesium ammonium phosphate)
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NH4MgPO4.6H20; Isobutylidenediurea (IBDU) - a single compound with the formula
(CH3)2CHCH(NHC(0)NH2)2 whereas the urea-formaldehydes consist of mixtures of
the
approximate formula (HOCH2NHC(0)NH)nCH2. animal wastes, plant wastes from
forest or
agriculture, and treated sewage sludge or biosolids, livestock manure(s),
products from the
slaughter of animals including blood meal, bone meal, feather meal, hides,
hoofs, horn etc.;
oxalates; aluminum sulfate, iron sulfate; fertilizer (acidifying/alkalizing,
containing ammonia -
such as ammonium nitrate, urea, or amino acids); peat moss, sphagnum peat;
rare earth(s); clays;
mud; soil; silicates; organic or inorganic deposits of biological matter;
diatom; other organic or
inorganic acidic or basic material; ligno-cellulosic material or waste,
molasses, starch, pitch,
surfactants, oil, hydrocarbons; pesticides, insecticides, herbicides,
fungicides and plant growth
regulators, solvent, solution, wax, polymers, binders, organic or inorganic
minerals, tar, asphalt,
buffering agent, oxidizing agent (chlorine, chlorine dioxide, hydrogen
peroxide, acid,
permanganates, sulfur dioxide, phenols, alcohols, oxyanions etc.), reducing
agent (e.g.
thiosulphate), anti-caking agent (e.g. magnesium hydrooxide), conditioner,
glycerin, glyceride,
existing product(s) in market, use of energy or rays (thermal, ultraviolet
light, ultrasonic,
electromagnetic, gamma etc.), pressure balance etc.; materials for controlled
release or fertilizers
encapsulation in a shell for degradation at a specified rate, such as Sulfur,
thermoplastics,
ethylene-vinyl acetate, surfactants, etc. to produce diffusion-controlled
release of nutrients.
"Reactive Layer Coating" for reactive monomers, fatty acid salts, paraffin,
topcoat material(s).
The pH control for the degree of acidity and alkalinity is measured on a scale
of 0-14, with a pH
of 7 is neutral, 0 to 7 is acidic, and 7 to 14 is alkaline. For example, the
ideal soil pH for
vegetables and lawn grasses is 6.5, just a little on the acidic side.
[0109] In an embodiment, a symbiotic algae system comprises: a pretreater
suitable for
producing a first effluent with reduced odor and biochemical oxygen demand; a
first algal
growth component fluidly coupled to the pretreater and receiving the first
effluent, wherein the
first algal growth component includes a heterotrophic algal growth strain, and
wherein the first
algal growth component produces a second effluent having nutrients and an off-
gas; and a
second algal growth component fluidly coupled to the first algal growth
component, and the
second algal growth component including at least one algal growth strain from
the group of: a
photoautotrophic algal growth strain, a mixotrophic algal growth strain, and a
heterotrophic algal
growth strain, and wherein the second algal growth component receives, as an
input, the second
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effluent and the off-gas and produces a third effluent. Additionally or
alternatively, the pretreater
is an anaerobic digester. Additionally or alternatively, the pretreater also
produces solid waste.
Additionally or alternatively, the symbiotic algae system further includes a
solid separator,
wherein the solid separator separates the first effluent from the solid waste.
Additionally or
alternatively, the solid waste is suitable for use as a fertilizer.
Additionally or alternatively the
symbiotic algae system further includes a phosphorus removal system.
Additionally or
alternatively, the phosphorus removal system alternates between anaerobic and
aerobic
conditions. Additionally or alternatively, wherein the phosphorus removal
system includes a
bacterium. Additionally or alternatively, the phosphorus removal system
includes a flocculation
stage. Additionally or alternatively, wherein the phosphorus removal system
includes a dissolved
air floatation stage. Additionally or alternatively, the symbiotic algae
system further includes a
struvite crystallization system, and wherein the first effluent and solid
waste are input into the
struvite crystallization system prior to delivery to the first algal
component. Additionally or
alternatively, the symbiotic algae system further includes an algal harvesting
system having at
least one separator, wherein the algal harvesting system is fluidly coupled to
the first algal
growth component and the second algal growth component. Additionally or
alternatively, the
algal harvesting system recovers an algal biomass suitable for use in a
fertilizer. Additionally or
alternatively, the fertilizer comprises: predominantly microalgae biomass
grown with the liquid
effluent from anaerobically digested manure; an ash and/or biochar; digestate
solids produced as
byproducts of digestion or co-digestion; and an additive for pH adjustment.
Additionally or
alternatively, the algal biomass is mixed with struvite and/or other nutrient
recovery solids.
Additionally or alternatively, the system has an EROI greater than 10.
Additionally or
alternatively, the system has an EROI of about 40. Additionally or
alternatively, the third
effluent and a second off-gas, both produced by the second algal growth
component, are received
as inputs to the first algal growth component.
[0110] In an embodiment, a symbiotic algae system comprises: a pretreater for
producing a first
effluent with reduced odor and biochemical oxygen demand; a first algal growth
component,
wherein the first algal growth component includes a heterotrophic algal growth
strain, and
wherein the first algal growth component produces a second effluent having
nutrients and an off-
gas; and a second algal growth component fluidly coupled to the first algal
growth component,
wherein the second algal growth component includes at least one algal growth
strain from the
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group of: a photoautotrophic algal growth strain, a mixotrophic algal growth
strain, and a
heterotrophic algal growth strain, and wherein the second algal growth
component receives, as
an input, the second effluent and the first off-gas and produces a second
effluent and a second
off-gas; and wherein the second effluent and the second off-gas are received
as inputs to the first
algal growth component. Additionally or alternatively the symbiotic algae
system further
comprising at least one biomass processing unit, the biomass processing unit
sized and
configured to extract lipids from at least one of the first algal growth
component and the second
algal growth component. Additionally or alternatively, the first algal
component removes a
portion of the nitrogen and the phosphorous from the second input and the
additional input.
Additionally or alternatively, the waste nutrient preparation sub-system
receives as an input an
effluent input or a waste input. Additionally or alternatively, the pretreater
is selected from the
group of: an anaerobic digester, a phosphorus removal system, a struvite
crystallization system, a
dissolved air floatation system, a nitrogen removal system, an ammonia
stripping system, a
combination of phosphorus and nitrogen removal system; a phosphorus removal
system
alternates between anaerobic and aerobic conditions, a phosphorus removal
system that includes
a bacterium, and a phosphorus removal system that includes a flocculation
stage, wherein the
pretreater recovers nutrients from the algal biomass and produces an effluent
which is returned to
the first algal component. Additionally or alternatively, the pretreater also
produces solid waste.
Additionally or alternatively the symbiotic algal system includes a solid
separator, wherein the
solid separator separates the effluent from the solid waste. Additionally or
alternatively, the solid
waste is mixed with the algal biomass and further adjusted to be suitable for
use a fertilizer.
Additionally or alternatively, the fertilizer or soil mix comprises: algal
biomass; an ash and/or a
biochar; a digestate solid; and an additive for pH adjustment. Additionally or
alternatively, the
effluent is sterilized and the algal biomass is further sterilized and dried.
Additionally or
alternatively, the first algal component is grown in a canal structure made
from light-penetrating
materials.
[0111] In another embodiment, a process for the manufacture of a fertilizer
product from a waste
stream comprises: selecting an algae strain based upon the composition of the
waste stream and a
desired extracted fertilizer component; growing an algal biomass from the
algae strain, using
portions of the waste stream as a feedstock; extracting a solids portion from
the algal biomass;
and preparing a fertilizer from the solids portion. Additionally or
alternatively, the process
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further includes the step of pretreating the waste stream using an anaerobic
digester. Additionally
or alternatively, the algal strain is chosen so as to remove either primarily
nitrogen or primarily
phosphorus. Additionally or alternatively, the process further includes
removing a portion of a
phosphorus component from the waste stream prior to growing the algal biomass.
Additionally
or alternatively, the removing is accomplished by an enhanced biological
phosphorus removal
system. Additionally or alternatively, wherein the enhanced biological
phosphorus removal
system alternates between anaerobic and aerobic conditions. Additionally or
alternatively,
wherein the enhanced biological phosphorus removal system includes a
bacterium. Additionally
or alternatively, wherein the enhanced biological phosphorus removal system
includes a
flocculation stage. Additionally or alternatively, wherein the enhanced
biological phosphorus
removal system includes a dissolved air floatation stage. Additionally or
alternatively, the
process further includes: mixing an ash and/or biochar in a desired ratio; and
adjusting the pH of
the with an additive. Additionally or alternatively, a fertilizer product is
manufactured by the
process. Additionally or alternatively, a solids component, harvested from the
waste stream, is
added to the fertilizer product to create a soil mix. Additionally or
alternatively, the growing the
algal biomass is completed in a symbiotic algae system. Additionally or
alternatively, the
symbiotic algae system includes: a first container for growing the algal
strain, wherein the algal
strain is a heterotrophic algal growth strain and wherein the algal strain
produces carbon dioxide
and a nutrient stream that is lacking a significant portion of the desired
extracted fertilizer
component; and a second container for growing a second algal strain, wherein
the second algal
strain is not the same as the algal strain and is selected based upon the
nutrient stream and a
desired extracted component and uses the carbon dioxide from the first
container. Additionally or
alternatively, a fertilizer product manufactured by the process. Additionally
or alternatively, a
solids component, harvested from the waste stream, is added to the fertilizer
product to create a
soil mix. Additionally or alternatively, the waste stream includes liquid
effluent from
anaerobically digested manure, and wherein the fertilizer comprises: algal
biomass; an ash and/or
biochar; digestate solids produced as byproducts of digestion or co-digestion;
and an additive for
pH adjustment. Additionally or alternatively, the second algal strain produces
oxygen and
wherein the oxygen is fed from the second container to the first container.
Additionally or
alternatively, the process further includes a pretreater for pretreating the
waste stream.
Additionally or alternatively, pretreater is selected from the group of: an
anaerobic digester, a
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phosphorus removal system, a struvite crystallization system, a dissolved air
floatation system, a
nitrogen removal system, an ammonia stripping system, a combination of
phosphorus and
nitrogen removal system; a phosphorus removal system alternates between
anaerobic and aerobic
conditions, a pyrolysis system, a phosphorus removal system that includes a
bacterium, and a
phosphorus removal system that includes a flocculation stage. Additionally or
alternatively, the
pretreater also produces a solid waste and a solids component suitable for a
soil mix.
Additionally or alternatively, the process further includes an algal
harvesting system having at
least one separator, wherein the algal harvesting system is fluidly coupled to
the first container
and the second container. Additionally or alternatively, the process further
includes processing
the waste stream with a struvite crystallization system prior to delivery of
the waste stream to the
algal biomass. Additionally or alternatively, the process further includes
mixing the algal
biomass with struvite. Additionally or alternatively, the process further
includes separating an
effluent component of the waste stream from a solid waste component of the
waste stream. The
process according to claim 1, wherein the algal biomass is grown in a canal
structure made from
light-penetrating materials. Additionally or alternatively, the process
further includes sterilizing
the algal biomass. Additionally or alternatively, the process further includes
separating solids
from the waste stream.
[0112] In another embodiment, a process for the manufacture of a fertilizer or
a soil mix product
from a waste stream comprising: selecting at least an algae strain based upon
the composition of
the waste stream and a desired extracted fertilizer or a soil mix; growing at
least an algal biomass
from the algae strain, using portions of the waste stream as a feedstock,
and/or harvesting
naturally growing algae from a reservoir; extracting a solids portion from the
algal biomass
and/or naturally growing algae; and preparing a fertilizer or a soil mix from
the solids portion.
[0113] Exemplary embodiments have been disclosed above and illustrated in the
accompanying
drawings. It will be understood by those skilled in the art that various
changes, omissions and
additions may be made to that which is specifically disclosed herein without
departing from the
spirit and scope of the present invention.
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