A techno-economic analysis of open pond microalgae biofuels production

J.R. Benemann1, I.C. Woertz1,2, and T.J. Lundquist1,2 1MicroBio Engineering, Inc., and 1,2California Polytechnic State University, San Luis Obispo, California, USA

Photographs Allowed (or ask for presentation] jbenemann@aol.com

J. Benemann, July 20, St. Louis, MO, Algal BBB

This techno-economic analysis is for a projected near-term 400 ha (1,000 acre) production system in S. California. The 4 ha (10 acre) raceway ponds are paddle wheel mixed; harvesting is by continuous settling (90% efficiency), followed by gravity thickening, solar drying, and hexane extraction of algal oils in a central facility. A productivity of 80 metric tons/ha-yr and a 25% extractable triglyceride content, ~50,000 barrels oil/year, is assumed. Biogas generated from residual biomass is used to generate electricity, with digester effluents recycled for nutrients (C, N, P, etc.) , with make-up water and nutrients supplied from local municipal wastewaters.. The engineering designs and construction costs, based on agricultural engineering practices, are estimated at ~$100 million with operating costs of $6 million per year (after sale of electricity of ~$1 million/yr), or $300/barrel (without wastewater treatment credits). Of this $60/bbl are for labor and $20/bbl for transport to/from the remote oil extraction facility. An on-site extraction process is needed. The main value of such studies is to help focus R&D on key 3 limiting factors and promising approaches for July future cost reductions. J. Benemann, 20, St. Louis, MO, Algal BBB

Abstract

We need a crystal ball

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J. Benemann, July 20, St. Louis, MO, Algal BBB

J. Benemann, July 20, St. Louis, MO, Algal BBB

Biofuels Digest, Jim Lane, June 21, 2011, Paris Air Show

UK-NY in 1 hour: algae-powered rocket plane

Airbus - Demo will fly by 2020!

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J. Benemann, July 20, St. Louis, MO, Algal BBB

Inoculum Tubes

First algal mass culture project (for Chlorella)

Plastic bag-type photobioreactors (PBRs)

Roof of MIT Building~ 1950

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2006, Austin, Tx

Jack Myers

Algae mass culture was first investigated over fifty years ago Carnegie Institute of Washington Algae for Food Project
First algae mass culture studies on MIT rooftop

Bessel Kok

1956, Stanford

10 Burlew (ed.) Algae Culture from Laboratory to Pilot Plant, 1953

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40 ha design based on 1950s MIT rooftop plant

Fisher (1956), A.D. Little Co. carried out an engineering design-cost estimate for a 40 hectare system of plastic tubes estimating (2008 $) capital cost >$1.25 million/ha
Still ~ what we estimate now for PBRs (best case) Thus 11 PBRs not considered herein J. Benemann, July 20, St. Louis, MO, Algal BBB

What is the alternative to high cost PBRs? High Rate Ponds: shallow raceway mixed ponds. Developed by Prof. Oswald, UC Berkeley early 1950s. First practical application, with recirculation pump mixing, in early 1960s at a municipal wastewater treatment plant (Concord, CA)

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During the 1950s Prof. W.J. Oswald pioneered high rate ponds (HRPs) for low-cost waste water treatment and biofuels production : shallow, raceway, slowly mixed ponds in 1970s) (paddle wheel mixing intruduced J. Benemann, July 20, St. Louis, MO, Algal BBB
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U.C. Berkeley, Richmond Field Station,

Sanitary Engineering Research Lab. ca 1976 1st use paddle-wheels for mixing large ponds (and of bioflocculation harvesting)

Microactinium

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THE MAJOR ISSUES IN MICROALGAE CULTIVATION (Most already well enough known in the 1950s]
Production Systems: Ponds vs. photobioreactors Productivity (solar conversion efficiency) g/m2-day or tons biomass/hectare-yr, how to maximize (light dilution) Oil production: very high content after N or Si limitation BUT very low productivity a still unresolved problem CO2 sources (need), supply, transfer (a very dismal topic) Mixing why mix, how much to mix, what energy input? Harvesting how, costs (< 500 ppm, <50 micron cells) Cultivation selected strains, grazers, weed algae, etc. Processing how dry, makeJ.biogas (oil extraction later) Benemann, July 20, St. Louis, MO, Algal BBB
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Cyanotech Co. Open, raceway ponds, algae plant in Hawaii. Red ponds for Haematococcus pluvialis for astaxanthin, others Spirulina

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Bird baths a selective environement for

Haematococcus pluvialis

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Raceway paddle wheel mixed high rate open ponds now the main (>99%) commercial production systems for microalgae

Spirulina

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Biodiesel Power Plant with CO2 Scrubber, 320 kW output can provide all the CO2 needed and most (~80%) of power needed

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Open ponds only option for algal biofuels production or wastewater treatment. One Question: how large can we make them?
Paddle wheel

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Design specs: 25-35 cm deep 20-30 cm/sec mix Dilute 20-40%/d 20 ~7.5-8.5 pH range

LOWEST COST BIOFUELS PRODUCTION SYSTEM

Lamellar settler harvesting

Sump for CO2 transfer Paddle wheel

Ponds, Christchurch NZ 5 hectares, 4 ponds Largest algae for biofuels project in world. Investigator: Dr. Rupert Craggs at NIWA J. Benemann, July 20, St. Louis, MO, Algal BBB
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Schematic of 1.25 ha ponds [Rupert Craggs, NIWA, NZ)

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Benemann, J.R. P. Pursoff, & W.J. Oswald, 1978. Engineering Design and Cost Analysis of a Large-Scale Microalgae Biomass System, Final Report US DOE. NTIS #H CP/T1605-01UC-61 (for methane only)

What might algae biomass cost to produce? Techno-economic studies of open pond production suggest low costs possible

Benemann, J.R., R.P. Goebel, J.C. Weissman, & D.C. Augenstein 1982. Microalgae as a source of liquid fuels. Final Report U.S.DOE BER Weissman, J.C., & R.P. Goebel, 1987. Design and analysis of microalgal open pond systems for the purpose of producing fuels Report to US DOE- SERI (fo the Aquatic Species Program) Benemann, J.R. & W.J., Oswald 1996, Systems and economic analysis of microalgae ponds for conversion of CO2 to biomass. Report to US DOE-NETL (National Technology Energy Laboratory) Lundquist, T., I. Woertz, N. Quinn and J. Benemann, 2010 (see next) Conclusion: algae biofuels maybe possible BUT NEED VERY HIGH 24 PRODUCTIVITIES, AND MANY OTHER FAVORABLE ASSUMPTIONS
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. . .
Straub et al. (eds.) Energy from Biomass (1982)
Tetraselmis Oscillatoria

Productivity during a continuous cultivation period of 18 months >50 t ha-1 yearPE: ~1.5% (Mario Tredici talk at this Conference)

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Productivity of Ponds in Calabria (M. Tredici]

m2-d

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One of better examples annual productivity with 26 open ponds

J. Sheehan, P. Roessler, T. Dunahay, J. Weissman J. Benemann (Principal Investigator)

Paul Roessler now

at Synthetic Genomics
(funded by ExxonMobil where Joe Weissman is) J. Benemann, July 20, St. Louis, MO, Algal BBB
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REQUIREMENT FOR COMMERCIAL PRODUCTION: Basic Schematic of Algae Biofuels Production based on wastewater inputs for water/nutrients

Lundquist, T., I. Woertz, N. Quinn and J. Benemann, 2010 A Realistic Technology and Engineering Assessment of Algae Biofuel Production, Energy Biosciences Inst., U.C. Berkeley 28
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Location of the Proposed Project (Imperial County, California

Imperial Valley
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Coachella Valley

Earthrise

Imperial Valley
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Assumed maximum hourly productivities to size CO2 supply ducts, blowers, spargers etc.
A lgal Biom ass Productivity (g/ m 2 / hr) 5 4 4 3 3 2 1 1 0 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov
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4 3.5 3 2.4

3.5 2.4

1 0.5

0.5

Dec

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Lundquist et al. 2010: Capital & operating cost estimates based mainly on agricultural, less on civil & not on chemical engineering practices
Construction techniques based on prior experience RS Means Construction Cost Data 2008 Also from recent S. California wastewater projects Operating costs from wastewater treatment plants

BOTTOM LINE: Algal oil production (no wastewater 32 treatment credits) costs would be ~$300/barrel J. Benemann, July 20, St. Louis, MO, oil. Algal BBB

Detailed C, N and Water Mass Balance, 400 ha system, wastewater make-up (full view)
Algae Settling Supernatant (Ave) 296,000 5,080 2,420 2,650 (Max) 349,000 7,250 3,440 4,190 Evaporation/ Volatilization (Ave) 32,400 36,000 9,720 406 (Max) 44,200 51,750 13,973 507 Supernatant of Algae Settling (Ave) 305,000 5,240 2,490 2,730 (Max) 360,000 7,470 3,550 4,320 Blowdown (Ave) 9,150 157 75 82 (Max) 10,800 224 106 130 Evaporation/ Volatilization Q (m3/d) N (kg/d) (Ave) 3,040 1,180 (Max) 4,330 1,690 Q (m3/d) Biomass (kg/d) C (kg/d) N (kg/d) Q (m3/d) CO2 (kg/d) CO2-C (kg/d) N (kg/d) Q (m3/d) Biomass (kg/d) C (kg/d) N (kg/d) Q (m3/d) Biomass (kg/d) C (kg/d) N (kg/d)

Make-Up Wastewater Q (m3/d) C (kg/d) N (kg/d) (Ave) 44,700 1,740 1,560 (Max) 59,300 2,310 2,080

Total Effluent

Subnatant of Algae Settling (Max) 368,000 149,000 71,000 9,640

Subnatant of Gravity Thickener (Max) 9,470 142,000 67,400 7,100

Algae High Rate Ponds

Q (m3/d) Biomass (kg/d) C (kg/d) N (kg/d)

(Ave) 312,000 105,000 49,800 7,710

2 Clarifier

Q (m3/d) Biomass (kg/d) C (kg/d) N (kg/d)

(Ave) 6,640 99,600 47,300 4,980

Algae Gravity Thickener

Q (m3/d) Biomass (kg/d) C (kg/d) N (kg/d)

(Ave) 3,160 94,700 45,000 4,730

(Max) 4,500 135,000 64,100 6,740

Drying Beds

Digester Effluent Q (m3/d) Biomass (kg/d) C (kg/d) N (kg/d) (Ave) 3,560 38,900 16,600 3,800 (Max) 5,070 55,400 23,700 5,410 CO2 (kg/d) CO2-C (kg/d)

Flue Gas (Ave) 144,000 38,880 (Max) 207,000 55,890

Natural Gas

Supernatant of Gravity Thickener (Max) 41,100 30,790 Q (m3/d) Biomass (kg/d) C (kg/d) N (kg/d) (Ave) 3,490 4,980 2,370 249 (Max) 4,970 7,100 3,370 355

Dried Algae Flakes Q (m3/d) Biomass (kg/d) C (kg/d) N (kg/d) (Ave) 118 94,700 45,000 3,550 (Max) 169 135,000 64,100 5,060

Generator

CH4 (kg/d) CH4-C (kg/d)

(Ave) 28,400 21,280

Electricity (Ave) Electricity From Nat Gas (MWh/d) Electricity From Biogas (MWh/d) 130 71 (Max) 189 101 Q (m3/d) CO2 (kg/d) CH4 (kg/d) CTotal (kg/d)

Biogas (Ave) 35,100 22,400 15,400 17,600 (Max) 50,000 32,000 21,900 25,100 Evaporation (Ave) Q (m3/d) 22 (Max) 31

Flash Dryer & Silo at Pond Site

Spent Algae

Spent Algae (Max) 103 101,000 48,100 5,060

Dried Algae 72 71,000 33,700 3,550

Anaerobic Digester

(Ave) Q (m3/d) Biomass (kg/d) C (kg/d) N (kg/d) 72 71,000 33,700 3,550

Silo at Pond Site

Q (m3/d) Biomass (kg/d) C (kg/d) N (kg/d)

Centralized Solvent Extraction Facility

Q (m3/d) Biomass (kg/d) C (kg/d) N (kg/d)

97 78,900 45,000 3,550

Mass Balance of Carbon, Nitrogen, and Water for Case 5. (400 ha algae facility)

Unrefined Oil from 1 400-ha Site Q (m3/d) Oil (kg/d) Oil (bbl/d) C (kg/d) 26 23,700 162 11,200

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Magnification of Mass Balance, 400 ha system, detail

Evaporation/ Volatilization (Ave) 32,400 36,000 9,720 406 Supernatant of Algae Settling (Ave) 305,000 5,240 2,490 2,730 Q (m3/d) CO2 (kg/d) CO2-C (kg/d) N (kg/d) (Max) 44,200 51,750 13,973 507 Q (m3/d) Biomass (kg/d) C (kg/d) N (kg/d) (Max) 360,000 7,470 3,550 4,320

Total Effluent

Algae High Rate Ponds

Q (m3/d) Biomass (kg/d) C (kg/d) N (kg/d)

(Ave) 312,000 105,000 49,800 7,710

(Max) 368,000 149,000 71,000 9,640

2 Clarifier

Flue Gas CO2 (kg/d) CO2-C (kg/d) (Ave) 144,000 38,880 (Max) 207,000 55,890

Natural Gas

Generator

CH4 (kg/d) CH4-C (kg/d)

(Ave) 28,400 21,280

(Max) 41,100 30,790

Electricity (Ave) Electricity From Nat Gas (MWh/d) Electricity From 130 71 (Max) 189 101 Q (m3/d) CO2 (kg/d) CH4 (kg/d)

Biogas (Ave) 35,100 22,400 15,400 (Max) 50,000 32,000 21,900

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Captial Cost CAPITAL COST FOR A 100 HECTARE FACILITY Highrateponds Digesters Extractionplantshare Dryingbeds Land Electrical Waterpiping Biogasturbine Flashdryer 2Clarifiers CO2delivery Roads+Fencing Thickerners Buildings Silostorage Vehicles Total 3,410,000 2,660,000 2,430,000 2,990,000 2,350,000 1,900,000 1,730,000 2,000,000 1,020,000 1,160,000 594,000 338,000 316,000 120,000 109,000 100,000 23,227,000
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add insurance, engineering, contingencies, management: = $33 million needed to construct a 100-ha facility

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$~3 million is the annual O&M cost

Operating Expenses Algae facility staff Extraction plant (staff and energy req.) Maintenance (2% cap.) Administrative staff Electricity purchasea Biomass haulingb Insurance Outside lab testing Vehicle maintenance Lab & office supplies Employee training Total operating expenses 694,000 478,000 465,000 375,000 379,000 239,000 180,000 50,000 15,000 12,500 10,000 $ 2,900,00036

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Technological Advances required for Biofuels

PRODUCTIVITY INCREASES (ANTENNA SIZE REDUCTION, see next slide for example) OIL CONTENT INCREASE (REGULATION) CONTROL WEED ALGAE, GRAZERS, OTHER CONTROL PROCESS OF BIOFLOCCULATION EXPAND TEMPERATURE LIMITS OF CULTIVATION WET EXTRACTION AND PROCESSING PRODUCE ANIMAL FEED CO-PRODUCT
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To increase productivity

A
WT CM2 CM1 CM1-1 CM7
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WT

Mutant

CM3

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CHALLENGE: ROTIFERS ( JUST ONE TYPE OF ALGAE GRAZER]

Must manage ponds for algal species & culture stability

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Nature already provides what some want to make (using genetic modifications and synthetic biology) oil globs made by the alga Botryococcus braunii

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WHY I AM OPTIMISTIC ABOUT MICROALGAE FUELS:

We now have wonderful tools

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We seem to have a few problems going from 42 lab-scale to full-scale production J. Benemann, July 20, St. Louis, MO, Algal BBB

On my planet, we only have one real word: Money (everything else are helper words)
Cartoon

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Greg Mitchell, SIO-UC San Diego

SEE YOU IN MINNESOTA, OCT 25-27

44 ALGAL BIOMASS SUMMIT -2011

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