ALLGAS Large scale algae cultures for biofuel production
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1 ALLGAS Large scale algae cultures for biofuel production H. Frühwirth, E. Kirl, R. Raudner, E. Ahn, F. Rogalla, M. Siebenhofer Symposium Energieinnovationen TU Graz , Graz
2 Outline Introduction BDI Algae Production Processes BioDiesel from Algae Allgas Project 2
3 BDI Headquarter BDI - BioEnergy International AG Parkring 18 A-8074 Grambach/Graz Austria/Europe 3
4 BDI at a Glance Diversified international customer base 1(1) 1(1) 4(3) 1(1) 1(1) 5(5) 3(1) 1(1) 1(1) 1(1) 6(3) 1(0) 1(1) 1(0) 1(0) 1(1) 1(1) Customers Fat and Meat Processing Industry Waste Disposal Companies Agriculture/Farmers Food Industry Brewing Industry Fresh Oil Producers (Vegetable Oil) Financial Investors 1(1) Mineral Oil industry 4(3) Number of plants ordered in the respective countries (figures in brackets denote number of Multi-Feedstock plants) Number of plants completed in the respective countries 28(21) (figures in brackets denote number of Multi-Feedstock plants) Target markets 4
5 Algae BDI Algaecultivation Downstream Conversion Lab scale reactors PCS Oil extraction/ purification Synergies to production of BioDiesel from difficult raw materials 5
6 Algae Production Processes 6
7 Principle Light source O 2 energy Biomass Mineral media Algal product Conversion CO 2 product by product 7
8 Reactor design Open cultivation Closed cultivation Horizontal tubes Novel concepts Open ponds Airlift reactors NASA, US Sapphire Energy, San Diego Klötze, Subitec, Germany 8
9 Energy balance Σenergy _ produced Net _ energy _ ratio = Σenergy _ requirements O. Jorquera, A. Kiperstock Comparative energy LCA of microalgal biomass production in open ponds and PBR, Bioresource Technology, 2009 Evodos centrifuges: Evodos Algae Harvester
10 BioDiesel from Algae 10
11 BioDiesel Process Transesterification CH 2 COOR CH 2 OH 40 C, 1 bar CHCOOR + 3 CH 3 OH CHOH + 3 RCOOCH 3 basic CH 2 COOR catalyst CH 2 OH triglycerid (fat) + 3 methanol glycerine + 3 fatty acid methyl ester Esterification R = fatty acid chain R-COOH + CH 3 OH R-COOCH 3 + H 2 O free fatty acid + methanol fatty acid methyl ester + water 11
12 BDI-Process Flow chart Catalyst solution Methanol Catalyst esterification Various Oils & Fats Esterification ME-Purification Qualitycontrol Methanol- Recovery BioDiesel EN Recyclemethanol Glycerine- Phase Fatty Acid Recovery Acid Crude Glycerine Preparation Phaseseparation Neutralisation Methanol- Recovery Solid Fertilitzer Drying Glycerine- Purification Pharma Glycerine Solid Fertilizer 12
13 Algae oil composition Possible raw material for BioDiesel production: Mono-, Di-, Triglycerides Fatty acids BioDiesel Impurities: solids, water, unsaponifiables, polymers, sulfur, phospholipids, phosphatides characteristics: free fatty acid content, fatty acid composition 13
14 Raw Material specification Crude algae oils are off spec in various parameters impurities fatty acid profil Unsaponifiable Total fatty acids Free fatty acid Water Insoluble substances Phosphorous Sulphur Polymerised triglycerides Polyethylene type plastics Iodine number Linolenic acid Polyunsaturated fatty acid (> 4 double bonds) Parameters used in specification for raw material entering the BDI BioDiesel process 14
15 Fatty acid composition fatty acid profil influence on BioDiesel quality, cold behaviour oxidation stability, iodine number content of polyunsaturated, linoleic acid rape seed animal fat palm oil algae oil (Chlor. ) algae oil (Diatom) C14: algae oil (Choryc.) C16: C16: C16: C18: C18: C18: C18: C20:1 >C20:n Comparison with different raw materials 15
16 Context Collaborative project Grant agreement no: Duration : 60 months Topic ENERGY : Biofuels from algae Coordinator: Aqualia, Frank Rogalla Project start
17 Overall process 17
18 Consortium Participant no. Participant organization name Role Country 1 (coordinator) Aqualia Gestión Integral del Agua S.A. Wastewater Spain 2 Feyecon/ Clean Algae S.L Cultivation, Extraction Netherlands /Spain 4 BDI - BioEnergy International AG Oil conversion Austria 5 Hygear B.V Biogas refinement Netherlands 6 MTD Alternative Energies Cultivation Turkey 7 University of Southampton Cultivation, Biogas UK 8 Fraunhofer Umsicht Analytics Germany 18
19 Algae cultivation site 19
20 Project coordinator: Aqualia Technical Experience > 300 Wastewater Treatment Plants: 500 M m 3 /a Nitrogen 50 mg/l = t/a Energy Consumption 0.5 kwh/m 3 = 250 MWh/a Energy in Nitrogen Fertilizer 15 kwh/kg N = 375 MWh/a Phosphorus 10 mg/l = 5000 t/a 20 Anaerobic Digestion Plants Biosolid Production: 125 M t/a Biogas Production from Biomass 2.2 M m 3 CH 4 10 kwh/m 3 = 22 MWh/a 20
21 Algae cultivation Algae cultivation on 10 ha 21
22 AllGas Oil - Workpackages 22
23 Process requirements PILOT tests of algae oil in 3 different BioDiesel production processes New catalysts Multifeedstock Repcat FhG BDI BDI Mass and energy balance Identification of challenges Assessment of process requirements DEMO in industrial scale Multifeedstock or Repcat in BDI plant 23
24 Workpackage 8 Pilot Scale experiments Pilot facility at BDI 24
25 Workpackage 9 Demo experiments beginning Sep
26 BDI BioDiesel Plants worldwide 26
27 Summary AIM Demonstration of sustainable production of biofuels based on low-cost microalgae cultures on large scale GOALS Full chain of processes Algal ponds: 10 ha site Biomass separation Processing for oil Biofuel production Use in vehicles MEANS Wastewater influent and nutrients will be re-used to stimulate algae growth. The extracted oils will be processed at an existing biodiesel plant. 27
28 28
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