Industrial Scale Demonstration Of Sustainable Algae Cultures For Biofuel Production

Industrial Scale Demonstration Of Sustainable Algae Cultures For Biofuel Production

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Description: Industrial Scale Demonstration Of Sustainable Algae Cultures For Biofuel Production: - Three large-scale demonstration projects for biofuel production from algae with ambitious targets: Implement a Demonstration plant, Annual productivity: 90 Ton/hect year, Biofuel testing in transportation applications.

 
Author: Zouhayr Arbib PhD  | Visits: 370 | Page Views: 515
Domain:  Green Tech Category: Biomass 
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Contents:
FP 7 All-gas
Project
Industrial scale demonstration
of sustainable algae cultures
for biofuel production
FROM WASTEWATER TO
BIOENERGY
Dr. Zouhayr Arbib
zouhayr.arbib@fcc.es
Head of sustainability area
Madrid, 14th December 2016
FCC Aqualia

1

0. INDEX

I.

Algae cluster: BIOFAT, InteSusAl & All-gas

II.

FP 7 All-gas objetives & main findings

III. Progress: DEMO is comming

IV. Conclusions: All-gas in a Football field

FCC Aqualia

2

0. INDEX

I.

Algae cluster: BIOFAT, InteSusAl & All-gas

II.

FP 7 All-gas objetives & main findings

III. Progress: DEMO is comming

IV. Conclusions: All-gas in a Football field

FCC Aqualia

3

0. INDEX

I.

Algae cluster: BIOFAT, InteSusAl & All-gas

II.

FP 7 All-gas objetives & main findings

III. Progress: DEMO is comming

IV. Conclusions: All-gas in a Football field

FCC Aqualia

4

0. INDEX

I.

Algae cluster: BIOFAT, InteSusAl & All-gas

II.

FP 7 All-gas objetives & main findings

III. Progress: DEMO is comming

IV. Conclusions: All-gas in a Football field

FCC Aqualia

5

Algae Cluster

6

I. Algae cluster

Three large scale demonstration projects for biofuel production
from algae with ambitious targets:

 Implement a Demonstration plant
 Annual productivity: 90 Ton/hect year
Biofuel testing in transportation applications

FCC Aqualia

7

I. Algae cluster

Three large scale demonstration projects for biofuel production
from algae with ambitious targets:

 Implement a Demonstration plant
 Annual productivity: 90 Ton/hect year
Biofuel testing in transportation applications

FCC Aqualia

8

I. Algae cluster

Three large scale demonstration projects for biofuel production
from algae with ambitious targets:

 Implement a Demonstration plant
 Annual productivity: 90 Ton/hect year
 Biofuel testing in transportation applications

FCC Aqualia

9

I. Algae cluster

Three large scale demonstration projects for biofuel production
from algae with ambitious targets:

 Implement a Demonstration plant
 Annual productivity: 90 Ton/hect year
 Biofuel testing in transportation applications

FCC Aqualia

10

I. Algae cluster

BIOFAT

All-Gas

InteSusAl

Cultivatio
n system

Green wall, open
ponds & PBRs

Open ponds

Fermentors, PBR and
open ponds

Water

Seawater

Wastewater

Seawater

Biofuels

Bioethanol /
Biodiesel

Biomethane

Biodiesel

Byproducts

Elect /heat

Wastewater treatment,
lipids, fertilizer,
elect/heat

Biomass for CHP or
further processing via
pyrolysis
FCC Aqualia

11

I. Algae cluster

BIOFAT

All-Gas

InteSusAl

Cultivatio
n system

Green wall, open
ponds & PBRs

Open ponds

Fermentors, PBR and
open ponds

Water

Seawater

Wastewater

Seawater

Biofuels

Bioethanol /
Biodiesel

Biomethane

Biodiesel

Byproducts

Elect /heat

Wastewater treatment,
lipids, fertilizer,
elect/heat

Biomass for CHP or
further processing via
pyrolysis
FCC Aqualia

12

I. Algae cluster

BIOFAT

All-Gas

InteSusAl

Cultivatio
n system

Green wall, open
ponds & PBRs

Open ponds

Fermentors, PBR and
open ponds

Water

Seawater

Wastewater

Seawater

Biofuels

Bioethanol /
Biodiesel

Biomethane

Biodiesel

Byproducts

Elect /heat

Wastewater treatment,
lipids, fertilizer,
elect/heat

Biomass for CHP or
further processing via
pyrolysis
FCC Aqualia

13

I. Algae cluster

BIOFAT

All-Gas

InteSusAl

Cultivatio
n system

Green wall, open
ponds & PBRs

Open ponds

Fermentors, PBR and
open ponds

Water

Seawater

Wastewater

Seawater

Biofuels

Bioethanol /
Biodiesel

Biomethane

Biodiesel

Byproducts

Elect /heat

Wastewater treatment,
lipids, fertilizer,
elect/heat

Biomass for CHP or
further processing via
pyrolysis
FCC Aqualia

14

I. Algae cluster

BIOFAT

All-Gas

InteSusAl

Cultivatio
n system

Green wall, open
ponds & PBRs

Open ponds

Fermentors, PBR and
open ponds

Water

Seawater

Wastewater

Seawater

Biofuels

Bioethanol /
Biodiesel

Biomethane

Biodiesel

Byproducts

Elect /heat

Wastewater treatment,
lipids, fertilizer,
elect/heat

Biomass for CHP or
further processing via
pyrolysis
FCC Aqualia

15

Objectives

& main findings

16

II. Objectives & findings

Free C, N and P

FCC Aqualia

17

II. Objectives & findings

5 Keypoints
when biofuels is the target

FCC Aqualia

18

II. Objectives & findings

5 Keypoints
when biofuels is the target

Low
CAPEX
PBRs

Avoid closed systens

FCC Aqualia

19

II. Objectives & findings

5 Keypoints
when biofuels is the target

Net Energy Ratio> 1

Low
CAPEX
PBRs

Avoid closed systens

Low OPEX
process

FCC Aqualia

20

II. Objectives & findings

5 Keypoints
when biofuels is the target

Net Energy Ratio> 1

Low
CAPEX
PBRs

Avoid closed systens

Low OPEX
process

No
fertilizers

Recycle N & P
1,5 Kg. de fuel-oil per Kg N
fixed (Haber-Bosh)

FCC Aqualia

21

II. Objectives & findings

5 Keypoints
when biofuels is the target

Net Energy Ratio> 1

Low
CAPEX
PBRs

Low OPEX
process

No
fertilizers

1st and 2nd
Generation biofuels

Avoid closed systens

Recycle N & P

Human
needs

FCC Aqualia

22

II. Objectives & findings

5 Keypoints
when biofuels is the target

Net Energy Ratio> 1

Low
CAPEX
PBRs

Low OPEX
process

No
fertilizers

1st and 2nd
Generation biofuels

Avoid closed systens

Recycle N & P

Human
needs

Sustainable process
Circular
economy

FCC Aqualia

23

II. Objectives & findings
All-gas process
WW

PUSH ®

DAF

Raceways

X

Digestion

CO2

CO2

X
CO2

X

Bacteria

X

>65%
upgrading
CH4

High energy production
>65%
High HRT
CH
CO2 addition
Complex process
4

>90%
CH4

X
Biofertilizers
FCC Aqualia

24

II. Objectives & findings
Simplified & Improved All-gas process

>65% CH4

CO2
Bacteria
>90%CH4

CNG

Biofertilizers
(high N and P)
FCC Aqualia

25

II. Objectives & findings
SCENARIO I:

SCENARIO II:

Figure
New Scenario1: Process flow diagrams of: SCENARIO I: With UASB pre-treatment of the raw wastewater;
advantages:
SCENARIO II: Without UASB pre-treatment

 Less investment costs (no UASB reactor)
 no CO2 injection (CO2 from bacteria activity)
 HRT reduced 50% (less land required )

 50 % more wastewater flow could be treated (More €)
 higher algae biomass production with better digestibility

New Scenario disadvantages:
 Less energy production in Scenario II
FCC Aqualia

26

From lab to DEMO

27

III. DEMO is comming

Pre-Demo

Pilot
plant
200m2

DEMO

Prototype
1000m 2

Basic
research
2011

2014

June
2016
February
2017

2010
FCC Aqualia

28

III. DEMO is comming

340 m
Total 5,8 Ha
Effective: 7X5200m23,64Ha
Under construction: 4X5200m2 2.1 Ha

170 m

FCC Aqualia

29

III. DEMO is comming
June 2016

November
2016

FCC Aqualia

30

III. DEMO is comming

Pond 2
18m width

294m

Pond 1
18m width

General
progress
50%
End
February

9m

9m

FCC Aqualia

31

III. DEMO is comming

2750 m3 AD
3XDAF
1X Centrifuge
1X Upgrading
1X Gas Station

FCC Aqualia

32

III. DEMO is comming
Digester (95%)

Hydrolysis & digestate tank
(100%)

DAF (90%)

Upgrading (60%)

Dewatering & boiler building
(75%)

General
progress
90%
End
February

FCC Aqualia

33

III. DEMO is comming

FCC Aqualia

34

CONCLUSIONS

All-gas in a Football field

35

IV. Conclusions
FP 7 All-gas
in a football Field
1 Hectare

FCC Aqualia

36

IV. Conclusions
FP 7 All-gas
in a football Field
1 Hectare

1000
m3/d WWT
(0,2€/m3)

FCC Aqualia

37

IV. Conclusions
FP 7 All-gas
in a football Field
1 Hectare

1000
m3/d WWT
(0,2€/m3)
950 m3/d
reuse
(0,3€/m3)

FCC Aqualia

38

IV. Conclusions
FP 7 All-gas
in a football Field
1 Hectare

1000
m3/d WWT
(0,2€/m3)
950 m3/d
reuse
(0,3€/m3)

0,3kWh/m3
energy
saving in
WWT

FCC Aqualia

39

IV. Conclusions
FP 7 All-gas
in a football Field
1 Hectare

1000
m3/d WWT
(0,2€/m3)
950 m3/d
reuse
(0,3€/m3)

0,3kWh/m3
energy
saving in
WWT
100 Ton/
year

FCC Aqualia

40

IV. Conclusions
FP 7 All-gas
in a football Field
1 Hectare

1000
m3/d WWT
(0,2€/m3)
950 m3/d
reuse
(0,3€/m3)

0,3kWh/m3
energy
saving in
WWT

30-40 kg
CH4/d

100 Ton/
year

FCC Aqualia

41

IV. Conclusions
FP 7 All-gas
in a football Field
1 Hectare

1000
m3/d WWT
(0,2€/m3)

> 360,000
km/year

950 m3/d
reuse
(0,3€/m3)

30-40 kg
CH4/d

0,25kWh/m3
energy
saving in
WWT
100 Ton/
year

FCC Aqualia

42

Biomethane from
Digestor Biogas

Smart green
gas project :
2 SEAT
vehicles

FCC Aqualia

43