An algae-based wastewater treatment system for the production of biodiesel, reclaimed water and energy

Authors: Jason Selwitz and Stephen Lyon

There is a need to lower the costs of wastewater treatment. Due to the developing air quality, public health, and ecological
degradation issues raised by the burning of fossil fuels, there is a renewed demand to develop alternative fuels for marine and land
based transportation. Locomotives, marine vessels, heavy equipment, and truck fleets all rely on diesel powered engines.
Approximately 75% of the cost of secondary wastewater treatment is for the pumping and aeration in the activated sludge process.
Developing a concurrent algae wastewater treatment and biodiesel production process could lower costs, improve emissions, lower
dependency on foreign oil, and provide an alternative to traditional wastewater treatment. Using filtered primary wastewater and an
algae-wastewater treatment system could produce a high quality effluent at a fraction of conventional treatment costs.

All planktonic algae produce oil in the form of triglycerides to keep them buoyant in the water column. In some species, the oil
content of the algae is 40-60% of its dry weight. The relatively simple mixture of the oil with sodium hydroxide and methanol plus
heat yields a commercially viable fuel. Biodiesel from algae produces far more fuel per acre of land than vegetable oil sources. As
predicted in the National Renewable Energy Lab’s (NREL) “Aquatic Species Program” close-out report, microalgal biodiesel will
become economically feasible once a rise in crude oil prices is seen, biodiesel subsidies and/or tax incentives are enacted, and fuel
production is paired with wastewater treatment. http://www1.eere.energy.gov/biomass/pdfs/biodiesel_from_algae.pdf

The algae-based biodiesel system:

Two strains of algae, Chlorella spp. and Botryococcus spp. are candidate species due to their percentage of oil and for their ability to
grow on primary wastewater. A residence time of five to seven days will yield algal biomass and a high quality effluent stripped of
nutrients. The first usable product in this process is the reclaimed water that can be sold for non-potable uses. The oil is separated
from the solid and aqueous fraction of the algae by physical and chemical processes. The purified oil is then converted to biodiesel
by conventional means. The addition of methanol and sodium hydroxide plus heat causes the breakdown of the triglycerides to form
esters, the main form of carbon in diesel fuel. The remaining biomass could then be used as a chemical feedstock for the production
of complex polymers. Another use for the biomass is that it could be added to the methane digester found at all large wastewater
treatment facilities. The additional biomass in turn helps to produce more methane that is burned to produce electricity. The exhaust
gases from the turbine are mainly carbon dioxide and nitrogen. Instead of venting the gas into the atmosphere, the exhaust is routed
into the algae culturing tanks. The exhaust gases are fed into an airlift system that allows for the complete capture of the gases by
the water and algae. This airlift system provides a means of constant circulation in the tanks without any moving parts. The end
products of this process are: 1. Reclaimed water fit for non-potable reuse 2. Biodiesel that can be used in all forms of diesel engines
3. Algal biomass that can be used as a chemical feedstock for the production of complex commercial polymers 4. Increased
electricity production from the methane digesters and elimination/reduction of carbon emissions from the energy producing turbines.
(The first phase of this research was completed at California State Polytechnic University-Pomona and was funded by the authors)
The sludge has a high N&P content and can be used as a fertilizer
Jason Selwitz was a graduate student in Regenerative Studies at CalPoly Pomona shown here with
different strains of algae growing on primary wastewater. This research was conducted at the John
T. Lyle Center for Regenerative Studies. http://www.csupomona.edu/~crs/ For a look at what is
happening around the planet regarding algae-based biodiesel production go to:
http://peswiki.com/index.php/Directory:Biodiesel_from_Algae_Oil
 ABSTRACT
Two strains of green, freshwater microalgae,
Chlorella protothecoides and Botryococcus braunii,
were used in experiments to determine whether they
could individually enhance the quality of one liter of
primary treated human wastewater. A third grouping
of algal strains, from Pond #6 at the John T. Lyle
Center for Regenerative Studies, was also utilized.
The protocol established called for analysis of the
algal oil content using gas chromatography/mass
spectrometry.
Over the course of five day residence times, water
quality improved as biochemical oxygen demand
was reduced, and ammonia was converted to nitrate.
Algal oils were produced and extracted, although
ratios of key fatty acid methyl esters were lower than
anticipated. Results from using specific strains of
algae to treat wastewater and produce biodiesel
caliber oil offer the foundation for future research.
While several projects throughout the world are
underway to commercialize production of biodiesel
from algae, the scientific literature recommends
pairing such efforts with wastewater treatment. As
climate change emerges, the need for expanded
reserves of water coincides with interest to develop
domestic sources of cleaner burning fuel.

Initial Algae-Wastewater-Biodiesel Research under the supervision of Dr. Stephen Lyon

The following is a hypothetical
modification of a wastewater
treatment facility.
Possible Reconfiguration of a Regional Wastewater Control
Facility to Yield Multiple Benefits

treatment wetlands
designed to remove
algae solids

A Regional Wastewater Control Facility discharges 30 MGD into a local river

 Free surface constructed post wetlands treatment includes:
wetlands designed to ammonia stripping towers, DAF,
remove algae solids chlorination, dechlorination and
discharge

Oxidation Pond #3

Oxidation Pond #1
Oxidation Pond #2

General flow patterns of the water from the treatment facility through the oxidation
ponds, wetlands and to the dissolved air flotation (DAF) tanks. The green line indicates
the flow of the concentrated algae solids back to the first oxidation pond.
Effluent from the
constructed wetlands
entering the DAF tanks
Algae sludge being concentrated at
the surface of the DAF chambers
before being pumped back to
oxidation pond #1.
 algae
filtration
system
photobioreactor provides
inoculum for the ponds

Theoretical reworking of the oxidation ponds where Hypalon® curtains with floating tops and
weighted bottoms allow for serpentine flow within each pond to develop more of a plug flow through
the three ponds. This allows for more thorough nutrient stripping by the algae. The influent to the
pond contains a pure strain of algae grown in photobioreactors. The algae are filtered off after
leaving oxidation pond #3 and the water goes through a final polishing stage in the constructed
wetlands.
Examples of large-scale algae culturing operations throughout the world
Examples of simple algae
concentration and processing
 What to do with the algae biosolids?
• All planktonic algae produce oil in the form of triglycerides to keep
them buoyant in the water column. In some species, the oil content
of the algae is 40-60% of its dry weight. For the algae in the oxidation
ponds it is assumed that the percentage of oil is 15%.
•The relatively simple mixture of the oil with sodium or potassium
hydroxide and methanol plus heat yields a commercially viable fuel.
Biodiesel from algae produces far more fuel per acre of land than
vegetable oil sources.
• The oil needs to be separated from the algae by various means
(chemical, mechanical, thermal, etc).
• The algae biomass can be added to the digester to produce more
methane.
• The flow chart on the next page shows the outcome of modifying
the current operations at the facility. The boxes with the double lines
indicate a beneficial end product.
 Constructed reclaimed
Wetlands wastewater
Effluent from separation of algae
Oxidation Pond #3 from the water

AB algae
oil
Exhaust gases are bubbled into the oxidation ponds to algae biomass
absorb carbon dioxide and promote algae growth,
possible carbon credits for removal of greenhouse gases
NaOH/KOH
methanol
heat*

Biodiesel
Electricity production via cogeneration
Chemical feedstock for
phytochemicals and/or
polymer production

* there are alternative biological, chemical and physical

Sludge digester for methane production processes that are being developed to produce biodiesel
The current TSS values leaving Oxidation Pond #3 are 30-70 mg/L. Under controlled
culturing conditions including the venting of carbon dioxide from the cogeneration plant
there could be a substantial increase in the algae biomass produced in the oxidation
ponds. Estimates are given below for the yield of oil and biosolids for a TSS range of
50-400 mg/L assuming an oil content of 15% of the dry weight of the algae. The oil
would go to biodiesel production and the biosolids could be used as a chemical
feedstock for polymer production or for more cogeneration by adding the algae
biosolids to the digester.
TSS TSS@ 30 MGD oil yield oil yield biosolids biosolids
mg/L KG total/day Kg of oil/day lbs/day tons/year lbs/day tons/year

(15%of TSS)

50 5677.50 851.63 1873.58 341.93 10616.93 1937.59

100 11355 1703.25 3747.15 683.85 21233.85 3875.18
200 22710 3406.50 7494.30 1367.71 42467.70 7750.36
300 34065 5109.75 11241.45 2051.56 63701.55 11625.53
400 45420 6813.00 14988.60 2735.42 84935.40 15500.71

e.g. 683.85 tons/year = 1,367,700 lbs/year ÷ 7.34 lbs/gal = 186,335 gal/year