benamotz
TRANSCRIPT
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Large Scale Open Algae Ponds
Ami Ben-Amotz The National Institute of Oceanography
Nature Beta Technologies Ltd. Nikken Sohonsha Co, Japan
Seambiotic Ltd. ISRAEL
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Commercial Open Ponds
Taiwan from round ponds (1960)
to oblong raceways (1970) mixotrophic cultivation
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Biology & Bio-Engineering Requirements for Maximal Productivity in Algal Open Ponds
•Location •Area layout •Pond design •Oblong raceways [length (10-300m), width (1-20m)] •Optimal size area (300-4,000m2) •Distal end, hydraulic radius •Ground infrastructure (area preparation) •Pond lining (none, clay, concert, asphalt, fiberglass, plastic sheeting, others) •Liquid flow (paddle wheels, pumps, airlift, moving board, others) •Paddle wheel •Outside walls and channel dividers •Flow velocity (laminar liquid flow velocity, 5-40 cm/sec) •Site control, pH control •Carbonation •Mixing & Turbulence •Depth (5-100cm, depth control) •Head loss, hydraulics, Manning’s “n” values •Pond accessories (drainage, cleaning, pumps, pipes)
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Biology & Bio-Engineering Requirements for Maximal Productivity in Algal Open Ponds
•Location •Area layout •Pond design •Oblong raceways [length (10-300m), width (1-20m)] •Optimal size area (300-4,000m2) •Distal end •Ground infrastructure (area preparation) •Outside walls and channel dividers •Depth (5-100cm, depth control) •Pond lining (none, clay, concert, asphalt, fiberglass, plastic sheeting, others) •Liquid flow (paddle wheels, pumps, airlift, moving board, others) •Paddle wheel (design, material, location, construction, units/pond area) •Flow velocity (laminar liquid flow velocity, 5-40 cm/sec) •Head loss, hydraulics, Manning’s “n” values •Mixing and Turbulence •Carbonation •Site control and pH control •Pond accessories (drainage, cleaning, pumps, pipes)
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Location? “Climatic regions most suitable for microalgae :
annual average temperatures of > 15 °C” (Benemann, 2007)
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Location? Earthrise, Imperial Valley, CA
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Location? Microbio Resources, Imperial Valley, Calipatria, CA
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Location? Nature Beta Technologies Ltd., Eilat, Israel
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Location? Cyanotech Corp. Hawaii, USA
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Location? Far East Chlorella and Spirulina
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Biology & Bio-Engineering Requirements for Maximal Productivity in Algal Open Ponds
•Location •Area layout •Pond design •Oblong raceways [length (10-300m), width (1-20m)] •Optimal size area (300-4,000m2) •Distal end •Ground infrastructure (area preparation) •Outside walls and channel dividers •Depth (5-100cm, depth control) •Pond lining (none, clay, concert, asphalt, fiberglass, plastic sheeting, others) •Liquid flow (paddle wheels, pumps, airlift, moving board, others) •Paddle wheel (design, material, location, construction, units/pond area) •Flow velocity (laminar liquid flow velocity, 5-40 cm/sec) •Head loss, hydraulics, Manning’s “n” values •Turbulence •Carbonation •Site control and pH control •Pond accessories (drainage, cleaning, pumps, pipes)
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Design U or Ellipsoid Pond?
pump, bubbling air or airlift? Oswald, Shelef & Melamed, USA & Israel, 1977
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Oswald (1983/4) System Design for 10 Acres
Dunaliella Production System
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Biology & Bio-Engineering Requirements for Maximal Productivity in Algal Open Ponds
•Location •Area layout •Pond design •Oblong raceways [length (10-300m), width (1-20m)] •Optimal size area (300-4,000m2) •Distal end •Ground infrastructure (area preparation) •Outside walls and channel dividers •Depth (5-100cm, depth control) •Pond lining (none, clay, concert, asphalt, fiberglass, plastic sheeting, others) •Flow velocity (laminar liquid flow velocity, 5-40 cm/sec) •Liquid flow (paddle wheels, pumps, airlift, moving board, others) •Paddle wheel (design, material, location, construction, units/pond area) •Head loss, hydraulics, Manning’s “n” values •Turbulence •Carbonation •Site control, pH control •Pond accessories (drainage, cleaning, pumps, pipes)
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Raceway Pond (Oswald 1984)
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Bio-Engineering Requirements for Maximal Productivity in Algal Open Ponds
•Area layout •Pond design •Oblong raceways [length (10-300m), width (1-20m)] •Optimal commercial size area (300-4,000m2) •Distal end •Ground infrastructure (area preparation) •Outside walls and channel dividers •Depth (5-100cm, depth control) •Pond lining (none, clay, concert, asphalt, fiberglass, plastic sheeting, others) •Flow velocity (laminar liquid flow velocity, 5-40 cm/sec) •Liquid flow (paddle wheels, pumps, airlift, moving board, others) •Paddle wheel (design, material, location, construction, units/pond area) •Head loss, hydraulics, Manning’s “n” values •Turbulence •Carbonation •Site control, pH control •Pond accessories (drainage, cleaning, pumps, pipes)
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Bio-Engineering Requirements for Maximal Productivity in Algal Open Ponds
Area Layout & Pond Design, set of 1 acre ponds (Oswald 1984)
Major items: Up & Down streams Overflow sumps Fresh water makeup Paddle wheels Carbonation CO2 feed lines Solids chamber Liquid lines Length, width, depth, slope, Screens
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Length, Width & Depth
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Length & Width 10 x 2 x 170 m = 3,400m2 (USA)
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Length & Width 10 x 2 x 150 m = 3,000m2 (Israel)
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Length & Width 10 x 2 x 150 m = 3,000m2 ?(USA)
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Scale Up, Length & Width 10 x 2 x 150 m = 3,000m2 (Israel, USA)
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Length & Width 5 x 4 x 150 m = 3,000m2
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Bio-Engineering Requirements for Maximal Productivity in Algal Open Ponds
•Area layout •Pond design •Oblong raceways [length (10-300m), width (1-20m)] •Optimal size area (300-4,000m2) •Distal end Hydraulic Radius •Ground infrastructure (area preparation) •Outside walls and channel dividers •Depth (5-100cm, depth control) •Pond lining (none, clay, concert, asphalt, fiberglass, plastic sheeting, others) •Flow velocity (laminar liquid flow velocity, 5-40 cm/sec) •Liquid flow (paddle wheels, pumps, airlift, moving board, others) •Paddle wheel (design, material, location, construction, units/pond area) •Head loss, hydraulics, Manning’s “n” values •Turbulence •Carbonation •Site control, pH control •Pond accessories (drainage, cleaning, pumps, pipes)
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Distal End, Hydraulic Radius
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Bio-Engineering Requirements for Maximal Productivity in Algal Open Ponds
•Area layout •Pond design •Oblong raceways [length (10-300m), width (1-20m)] •Optimal size area (300-4,000m2) •Distal end, hydraulic radius •Ground infrastructure (area preparation) •Pond lining (none, clay, concert, asphalt, fiberglass, plastic sheeting, others) •Outside walls and channel dividers •Depth (5-100cm, depth control) •Flow velocity (laminar liquid flow velocity, 5-40 cm/sec) •Liquid flow (paddle wheels, pumps, airlift, moving board, others) •Paddle wheel (design, material, location, construction, units/pond area) •Head loss, hydraulics, Manning’s “n” values •Turbulence •Carbonation •Site control, pH control •Pond accessories (drainage, cleaning, pumps, pipes)
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No liner Clay
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Asphalt
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PVC & PE
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PVC, under liner geo-textile
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300 m2 Pond
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PVC 3,000m2
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PVC Liner 20 Years Old Durable (20 years), UV resistant, Low “n”
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Biology &Bio-Engineering Requirements for Maximal Productivity in Algal Open Ponds
Pond lining None, leak Clay, leak, anaerobic areas Concert, break Asphalt, disintegrate Fiberglass, expensive Rubber, ?? High density polyethylene (HDPE), break, high temperature expansion coefficient Polyethylene, ok, low “n” but welding problem Polypropylene, ok, low “n” PVC (technical grade, food grade), ok, low “n” PVC, Geo-textile underline, may be needed PVC, UV resistance, ease of maintenance, simlpe welding, durable
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Biology & Bio-Engineering Requirements for Maximal Productivity in Algal Open Ponds
•Area layout •Pond design •Oblong raceways [length (10-300m), width (1-20m)] •Optimal size area (300-4,000m2) •Distal end, hydraulic radius •Ground infrastructure (area preparation) •Pond lining (none, clay, concert, asphalt, fiberglass, plastic sheeting, others) •Liquid flow (paddle wheels, pumps, airlift, moving board, others) •Paddle wheel •Outside walls and channel dividers •Depth (5-100cm, depth control) •Flow velocity (laminar liquid flow velocity, 5-40 cm/sec) •Head loss, hydraulics, Manning’s “n” values •Turbulence •Carbonation •Site control, pH control •Pond accessories (drainage, cleaning, pumps, pipes)
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Biology & Bio-Engineering Requirements for Maximal Productivity in Algal Open Ponds
The Paddle wheel • “Inefficient pump” or independent impeller • Location • Design • Construction • Shaft & blades material (stainless steel, fiberglass, marine
plywood, others) • Number of blades • Diameter • Bottom to paddle distance • Paddle in liquid (perimeter & angle, immersion in culture) • Salt incrustation (water washing) • Motor, gear, rpm (5-30rpm) • Maintenance (weight, lifting, lift distance) • Units/pond • Units/area
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The One Unit Paddle Wheel Oswald (1983)
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The Paddle Wheel Location and Design
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The Paddle Wheel one unit fiberglass paddle (Oswald)
or the divided blades motors & gears
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The Paddle Wheel Material Blades made of plastic, metal or
marine plywood (Dodd)
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The Paddle Wheel Dimensions Length: 10 or 5 meters?
One of 5 or 10m, or two of 5m? Diameter: 30 to 120cm?
Blades shape & size? Immersion & angel?
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The Spirulina Paddle Wheel short diameter (30 cm), high rpm
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Spirulina paddle long, short diameter, high rpm
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The Paddle Wheel location, design, direction?
two or one in pond?
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Paddle Wheel flow direction?
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The “Island” design and area?
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Pond Optimization paddle wheel/pond area?
Oswald: one paddle/3,400m2
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Immersion, Angel and Ground how many blades in culture at time (2/8;3/8;2/6)? distance to ground?
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Biology &Bio-Engineering Requirements for Maximal Productivity in Algal Open Ponds
•Area layout •Pond design •Oblong raceways [length (10-300m), width (1-20m)] •Optimal size area (300-4,000m2) •Distal end, hydraulic radius •Ground infrastructure (area preparation) •Pond lining (none, clay, concert, asphalt, fiberglass, plastic sheeting, others) •Liquid flow (paddle wheels, pumps, airlift, moving board, others) •Paddle wheel •Outside walls and channel dividers •Depth (5-100cm, depth control) •Flow velocity (laminar liquid flow velocity, 5-40 cm/sec) •Head loss, hydraulics, Manning’s “n” values •Turbulence •Carbonation •Site control, pH control •Pond accessories (drainage, cleaning, pumps, pipes)
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Outside walls and channel dividers concrete?
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Outside walls and channel dividers bricks?
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Biology & Bio-Engineering Requirements for Maximal Productivity
in Algal Open Ponds •Area layout •Pond design •Oblong raceways [length (10-300m), width (1-20m)] •Optimal size area (300-4,000m2) •Distal end, hydraulic radius •Ground infrastructure (area preparation) •Pond lining (none, clay, concert, asphalt, fiberglass, plastic sheeting, others) •Liquid flow (paddle wheels, pumps, airlift, moving board, others) •Paddle wheel •Outside walls and channel dividers •Flow velocity (laminar liquid flow velocity, 5-40 cm/sec) •Depth (5-100cm, depth control) •Head loss, hydraulics, Manning’s “n” values •Turbulence •Carbonation •Site control, pH control •Pond accessories (drainage, cleaning, pumps, pipes)
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Laminar Flow Velocity Oswald: ~30cm/sec
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Biology & Bio-Engineering Requirements for Maximal Productivity
in Algal Open Ponds •Area layout •Pond design •Oblong raceways [length (10-300m), width (1-20m)] •Optimal size area (300-4,000m2) •Distal end, hydraulic radius •Ground infrastructure (area preparation) •Pond lining (none, clay, concert, asphalt, fiberglass, plastic sheeting, others) •Liquid flow (paddle wheels, pumps, airlift, moving board, others) •Paddle wheel •Outside walls and channel dividers •Flow velocity (laminar liquid flow velocity, 5-40 cm/sec) •Site control, pH control •Depth (5-100cm, depth control) •Head loss, hydraulics, Manning’s “n” values •Turbulence •Carbonation •Pond accessories (drainage, cleaning, pumps, pipes)
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PC Site Control Technology control: paddles, pumps, pipes, gases, sensors, liquids Biology information & control: pH, depth, CO2 flow, temperatures,
liquid transfer
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Site Control & Operation liquids transfer control at 60m3/hr
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Dedicated Pond Control
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CO2 pH Control depth control & sensors (wired, wireless)
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pH Control, 10 Hectares
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Biology & Bio-Engineering Requirements for Maximal Productivity
in Algal Open Ponds •Area layout •Pond design •Oblong raceways [length (10-300m), width (1-20m)] •Optimal size area (300-4,000m2) •Distal end, hydraulic radius •Ground infrastructure (area preparation) •Pond lining (none, clay, concert, asphalt, fiberglass, plastic sheeting, others) •Liquid flow (paddle wheels, pumps, airlift, moving board, others) •Paddle wheel •Outside walls and channel dividers •Flow velocity (laminar liquid flow velocity, 5-40 cm/sec) •Site control, pH control •Carbonation •Depth (5-100cm, depth control) •Head loss, hydraulics, Manning’s “n” values •Turbulence •Pond accessories (drainage, cleaning, pumps, pipes)
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Carbonation counter current carbonation chamber
(Oswald 1983) (Theoretical use: ~ 2g CO2/gr AFDW algae)
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Carbonation
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pH & Alkalinity Control HCl & CO2
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pH Control, Depth, Temp recording history
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Bio-Engineering Requirements for Maximal Productivity
in Algal Open Ponds •Area layout •Pond design •Oblong raceways [length (10-300m), width (1-20m)] •Optimal size area (300-4,000m2) •Distal end, hydraulic radius •Ground infrastructure (area preparation) •Pond lining (none, clay, concert, asphalt, fiberglass, plastic sheeting, others) •Liquid flow (paddle wheels, pumps, airlift, moving board, others) •Paddle wheel •Outside walls and channel dividers •Flow velocity (laminar liquid flow velocity, 5-40 cm/sec) •Site control, pH control •Carbonation •Mixing & Turbulence •Depth (5-100cm, depth control) •Head loss, hydraulics, Manning’s “n” values •Pond accessories (drainage, cleaning, pumps, pipes)
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Mixing by liquid flow velocity of ~0.5 ft./sec?
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Flow, Mixing or Turbulence? Key Factors for High Productivity
(both channels at 30cm/sec)
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Mixing O2 and CO2
O2 super saturation?
(Nurdogan & Oswald, 1983)
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Biology & Bio-Engineering Requirements for Maximal Productivity
in Algal Open Ponds •Area layout •Pond design •Oblong raceways [length (10-300m), width (1-20m)] •Optimal size area (300-4,000m2) •Distal end, hydraulic radius •Ground infrastructure (area preparation) •Pond lining (none, clay, concert, asphalt, fiberglass, plastic sheeting, others) •Liquid flow (paddle wheels, pumps, airlift, moving board, others) •Paddle wheel •Outside walls and channel dividers •Flow velocity (laminar liquid flow velocity, 5-40 cm/sec) •Site control, pH control •Carbonation •Mixing & Turbulence •Depth (5-100cm, depth control) •Head loss, hydraulics, Manning’s “n” values •Pond accessories (drainage, cleaning, pumps, pipes)
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Head Loss & Depth at 0.5 ft/sec
“n” inches/1,000ft channel length
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Oswald’s Pond Design, 1983
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Biology & Bio-Engineering Requirements for Maximal Productivity
in Algal Open Ponds •Area layout •Pond design •Oblong raceways [length (10-300m), width (1-20m)] •Optimal size area (300-4,000m2) •Distal end, hydraulic radius •Ground infrastructure (area preparation) •Pond lining (none, clay, concert, asphalt, fiberglass, plastic sheeting, others) •Liquid flow (paddle wheels, pumps, airlift, moving board, others) •Paddle wheel •Outside walls and channel dividers •Flow velocity (laminar liquid flow velocity, 5-40 cm/sec) •Site control, pH control •Carbonation •Mixing & Turbulence •Depth (5-100cm, depth control) •Head loss, hydraulics, Manning’s “n” values •Pond accessories (drainage, cleaning, pumps, pipes)
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Pond Cleaning Machine use: fast, simple, efficient
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Location? (Oswald 1983)
Light & Temperature, Winter & Summer
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Location? Climatic regions most suitable for microalgae :
annual average temperatures of > 15 °C” (Benemann, 2007) Optimal: 4-10 night °C, 10-22 day °C
Higher lipid Content Less contamination
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Location? Spring Conditions
low night temp, moderate day temp
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Biology & Bio-Engineering Requirements for
Maximal Productivity in Algal Open Ponds
Oswald Design 25 years later
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Biology & Bio-Engineering Requirements for Maximal Productivity in Algal Open Ponds
•Location, same like higher plants •Area layout, as available, preferred lower temperatures •Pond design, raceways •Oblong raceways [length (10-300m), width (1-20m)], 5m x 150m •Optimal size area (300-4,000m2), 1,500m2 by one paddle •Distal end, hydraulic radius, necessary •Ground infrastructure (area preparation), at minimum cost •Pond lining (none, clay, concert, asphalt, fiberglass, plastic sheeting, others), PE or PVC at low “n” •Liquid flow (paddle wheels, pumps, airlift, moving board, others), paddle wheel (or?) •Paddle wheel, XXXX? •Outside walls and channel dividers, the cheapest (bricks, ground ramps) •Flow velocity (laminar liquid flow velocity, 5-40 cm/sec), 30cm/sec ? •Site control, pH control, essential •Carbonation, 2-5 mM TDC at pH 7-8 •Mixing & Turbulence, important (why, how?) •Depth (5-100cm, depth control), the minimum possible in large ponds •Head loss, hydraulics, Manning’s “n” values, low “n” •Pond accessories (drainage, cleaning, pumps, pipes), essential •Essentials at low cost: nutrients, CO2, sea water (salt), electricity, energy •Crop protection
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Photosynthetic Limitation of Long Term Algal Productivity Max Theoretical Algal Productivity
25 g/m2/day
Environment Factor Reduction (%) Solar light ------ 100 Scattering and reflecting properties of surface 10% 90 Absorption spectrum (depth of culture) 50% 45 Photosynthetic efficiency (25%) 75% 11.3 Light saturation (7-95%) 60% 4.5 Respiration, photo-respiration, excretion 5% 4.3 Photo-inhibition 10% 3.8 Temperature 20% 3.1 ================================== ===========================
Productivity Mean daily solar intensity 4,000 kcal/m2/day Energy productivity at 3% efficiency 120 kcal/m2/day Algal biomass productivity (5 kcal/g) 25 g/m2/day
Higher Plants Max (sugar cane, corn, wheat, etc.) 5 g/m2/day
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The Israel Electric Co/Seambiotic Ltd. Pilot Plant, Israel
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The Israel Electric Co/Seambiotic Ltd. Pilot Plant, Israel
Low Cost Production of marine
Nannochloropsis at yearly average
20g biomass/m2/day (~ 30% lipids)
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Thanks to: SEAMBIOTIC Ltd.
& ISRAEL ELECTRIC CO
•