1. Serving Clients One Breakthrough at a Time
Algae Photobioreactor Design Considerations for Commercial Scale Production
Presented by:
Greg Karr
Serving Clients One Breakthrough at a Time

2. State of the Industry (Algae Farming)
Current
Future
Traditional Farming: 50 – 70 years
Algae Farming: 5-7 years (so far)

3. Assumption: Algae industry stays alive
1930’s Farming or 2009 Algae
Current
Future
Crops can and are grown and harvested
Require high inputs per yield, labor/energy
Large scale operations not feasible or even possible
Equipment improvements will increase yields and decrease production costs
Production methods will continually be refined and made more efficient
Biotech will drive yields up and increase value of specific products
Assumption: Algae industry stays alive

4. MRI Florida raceway open pond
Lower tech, well known technology
Lower capital costs
Lower operational and maintenance costs
Limited ability to control
Temperature (low side)
Species selection
Seasonal flucuations
Evaporation losses
Lower production rates, yields and product value
Production rates and product values do not offset costs (under normal conditions)
MRI Florida raceway open pond

5. Closedloop PBR’s Higher tech, generally unproven
Much higher capital costs
Higher operational costs and maintenance costs
Offers higher level of control
Temperature (low side)
Species selection
Evaporation losses
Offers potential for higher production rates and higher value products
Billion $ question: Can the higher production rates ever justify the extremely large capital and operational costs?
MRI KC AlgaeLink PBR, 3500 L

6. Capital Costs Unit basis ($ cost/$ revenue)
Higher
Lower
Investment Risk Land Usage Light Collection Service Life Production Controls Productivity Product Value (species selection)

7. Operational Costs Unit basis ($ cost/$ revenue)
Higher
Lower
Labor
Maintenance
Utilities
Water source
Growth Nutrients
Gas input (source and energy)
Culture Maintenance

8. Revenues Adding Value Lower Value
Biomass Combustion Animal Feed Algal Oil Liquid Biofuel Feedstocks (starches/celluloses) High Value Compounds Waste reduction (water/fertilizers) CO2 mitigation

9. Issues Not Discussed Here
Harvesting
All current methods are less than ideal
Governmental Influences
Subsidies
Regulation
Energy Market Fluctuations
Competing Technologies
Implications of GMO algal species

10. What is the optimal PBR Design Balance?
Answer: It depends
Regional and site specific
Variable input characteristics
Must be ready to adjust and make trade offs to achieve the most profitable system possible.

11. Questions?