Wenqiao (Wayne) Yuan1, ZJ Pei2

1Biological and Agricultural Engineering

2Manufacturing and Industrial System

Engineering

Kansas State University

1,600 gal acre-1 year-1 3,100 gal acre-1 year-1

6,500 gal acre-1 year-1

Why algae Productivity: potentially high End product: transportation fuels Scalability: billion-gallon capacity

Problem Cost: very high - $3,000/dry ton Acceptable cost: <$300/dry ton Why?

Open ponds Low productivity: 2 g/m2-day? Harvesting is a big issue

PBRs? Construction cost is enormously high Harvesting is still a problem

Algae Biofuel Manufacturing in the Ocean (CMMI-0836610)(SGER-Exploratory research on solid carriers for manufacturing algae biofuels in the ocean)

Idea for Meeting the Challenge Algae ocean farming

Why? “Land”, water, air, sunlight, temperature … Harvesting/dewatering is “easier”

Approach Grow algae on/in solid carriers in the ocean

Manufacturing Challenge What algae species? What type of solid carrier materials? What designs of solid carrier?

SpeciesNanochloropsis sp.Spirulina platensisUlva lactucaPleutochrysis carteraeScenedesmus dimorphus

Carrier Materials Polystyrene Polyurethane Polyethylene Construction fabric

How Rocking shaker system Column reactor

Fundamental research needed Mechanism of attachment? Self-aggregation mechanism? Coating? Electrostatic? Special membrane or polymer matrix?

(A. Ben-Amotz, 2008)

17.5%12.5%

20%

50%

(Q. Hu and M. Summerfeld, 2008)

Specific challenge Algae lipid extraction Algae biomass residue utilization

Idea for Meeting the Challenge An integrated algae biomass refinery

Approach Wet grinding milling for cell disruption Drum drying and extrusion for flaking Counter-current solvent extraction Protein/carbohydrate separation

What is the Manufacturing Challenge Wet grinding mill Drum dryer Flake extrusion equipment Oil extraction facility

Algae Biorefinery