Vertical bioreactor technical methods, systems, and processes

Abstract

Embodiments may provide a photobioreactor system, such as a vertically growth-promoting mixed spectrum photobioreactor (1), including but not limited to at least one downcomer tower (22) having a helical indentation (211), a riser tower (21), an algae fluid input (10), an algae downward fluid flow (25) in the downcomer tower; a gas input (18) for driving a system flow (250), an upflow (20) of gas in the riser column; a carbon dioxide gas input (27) having a carbon dioxide mass flow lower than the mass flow in the riser column, a carbon dioxide gas upflow (26) in the downcomer column; a counter flow (230) created with the downward flow of algae and the upward flow of carbon dioxide gas; and may even be used to dehydrate algae. Each photobioreactor system may be connected to provide a plurality of photobioreactor systems that may be automatically controlled.

Description

[0001] This application is a PCT patent application claiming the priority and benefit of U.S. Provisional Patent Application No. 63 / 416,562, filed on October 16, 2022, which is hereby incorporated by reference in its entirety. Technical Field

[0002] Embodiments of the present application relate to enhanced growth-promoting hybrid spectrum (“GEMS”) hybrid technologies with algae and carbon dioxide utilization. Vertical photobioreactors can be used to efficiently grow algae driven by air or flue gas containing carbon dioxide. In some embodiments, a combination of vertical and horizontal tubes may be optimal. Background Art

[0003] The power generation industry is facing increasing pressure in generating electricity from renewable energy sources. Many biofuels meet the renewable energy standards; however, sources of conventional biofuels, such as biomass, biodiesel, bioethanol, and biogas, may not be geographically evenly distributed across the country and the world, and generally, these sources may not be close to power generation facilities. At the same time, reducing carbon dioxide emissions and other gas emissions from various sources is becoming increasingly necessary and desirable. In addition, the imposition or even potential imposition of a carbon tax can make carbon capture and utilization even more economically desirable. Generally, capturing carbon dioxide from the flue gas of anthropogenic sources, such as power plants, and then sequestering it can be expensive, and the long-term results may be uncertain (e.g., the earth may shake and the gas may be released again, groundwater supply pollution, etc.).

[0004] On the other hand, photosynthesis is the way nature recycles carbon in the biosphere. In this process, photosynthetic organisms, such as plants, can use sunlight, carbon dioxide, and nutrients to synthesize carbohydrates, proteins, oils, and other cellular materials. One of the most efficient converters of carbon dioxide (“CO2”) into biomass may be microalgae when using solar energy in the presence of nutrients. Algae may be the fastest-growing photoautotrophs on earth and may even be one of the simplest microorganisms in nature.

[0005] Using algal biotechnology, carbon dioxide capture can be beneficial because of the production of useful high-value products, the productivity of which can be enhanced by using carbon dioxide that would otherwise be emitted as waste gas into the atmosphere and cause global warming. Producing algal biomass as a means of reducing the level of carbon dioxide in combustion gases can be an attractive concept. Algal biomass can also be converted by known thermochemical conversion techniques into high-quality liquid fuels that can be similar to crude oil, such known techniques being, for example, high-temperature liquefaction (which may require the provision of waste heat and low-cost electricity to be done economically), or conversion into diesel fuel (e.g., biodiesel) via transesterification of the lipids of algal biomass, or even conversion into renewable diesel and jet fuel via modified oil refining. Algal biomass can also be used for gasification to produce highly flammable organic fuel gas suitable for gas-fired power plants. Algae can produce ethanol. The proteins and omega-3 fatty acids in algal biomass can make it a good source of food, fish feed, and even animal feed.

[0006] Algal cultures can also be used to remove biological nitrogen oxides (“NOx”) from combustion gases. Some algal species can remove NOx over a wide range of NOx concentrations and combustion gas flow rates. Nitric oxide (NO), a major NOx component, can dissolve in the aqueous phase, after which it can be oxidized to nitrogen dioxide (“NO2”) and even assimilated by algal cells. For example, the removal of NOx using the alga Dunaliella can be carried out under both light and dark conditions, with a NOx removal efficiency of more than about 96% (such as under light conditions).

[0007] Over an 18-year period, the U.S. Department of Energy (“DOE”) funded a large amount of research to develop renewable transportation fuels from algae. In Japan, government organizations such as the Ministry of International Trade and Industry, together with private companies, invested more than $250 million in algal biotechnology. Each program adopted a different approach, but due to the various problems addressed herein, to date, there has been little success on a large-scale commercial basis.

[0008] An additional valuable use of algae can be the production of high-protein fish feed that can restore their fatty acids. The demand for fish farms may increase rapidly, and the availability of fish for feeding other fish (such as salmon, etc.) may decrease. Therefore, many farms use soybeans and other plant proteins for feed, but these alternatives do not contain the omega-3 fatty acids that make these farmed fish valuable food. Algae have these fatty acids and can thus be valuable fish feed.

[0009] In addition, algae can grow in brackish water and even in salt water that may not be suitable for agriculture. This can achieve all the advantages of algae production without potentially causing serious water use problems.

[0010] The main obstacle to viable algae carbon dioxide capture and even potential pollution elimination is the lack of efficient and cost-effective growth systems. DOE's research focus has been on growing algae in large open ponds of about 4 km 2 In 2016 alone, the final report of the National Algal Biofuels Technology Review (a major 3-year US government-funded program) concluded that "the cultivation of algae in algal channels and open ponds is considered the most economical pathway for algal biomass and biofuel production. In the coming decades, if biofuels of the expected scale are to be produced, algae will have to be cultivated on thousands of acres of land for the required biomass production." This is the result of examining many closed photobioreactor designs. Basically, raceway ponds may require low capital investment; however, algae grown in open and uncontrolled environments may have low algal productivity mainly due to self-shading, which may occur because algae near the surface receive sunlight, grow and darken, and create a shadow over the algae in the pond deeper below the surface. This is due to the fact that within a few diameters of the paddlewheel propulsion system, the turbulence it generates decays, and for most of the length of the raceway pond, there is little mixing that brings algae from deeper in the pond to the surface and also moves the algae at the surface to deeper in the pond. Additionally, slower-growing algal species may contaminate the pond due to possible contamination by environmental predators. Occasionally, sudden pond deaths are experienced. Open pond technology seems to make growing and harvesting algae too expensive, perhaps because the movement of large volumes of dilute algal water may require very large agitators, pumps, collectors, and the low concentration of algae requires energy-intensive drying, etc.

[0011] To mitigate the above effects, major efforts have been made to examine and understand the nature of the biological factors (such as bacteria, viruses, invasive algal species, fungi, and even herbivores) in algal ponds that may affect algal biomass production, and some progress has been made.

[0012] Another difficulty in using ponds to address point-source emissions of carbon dioxide may be due to the shallow pond depth, as carbon dioxide rises to the surface and re-enters the atmosphere before algae can fully utilize it.

[0013] New methods must overcome the limitations faced in current industry, which may include generally low areal productivity or even productivity per unit area (which may be far less than the theoretical maximum), as well as issues related to scaling up microalgae cultures to commercial scale. In the past, attempts have been made to scale up closed photobioreactors to industrial and commercial scale. As with open raceway ponds, a key issue to address may be to generate mixing motion such that all algae can see the light entering the walls, which is necessary for uniform growth of algae in these large volume systems as the algae become denser. Lack of large-scale mixing of dense algae in large systems will prevent light from reaching the algae in the middle of the system (usually tubes). Summary of the Invention

[0014] This application includes multiple aspects that can be selected in different combinations based on specific applications or needs to be addressed. In various embodiments, this application may include a vertical photobioreactor for algae growth, or a combination of vertical and horizontal units.

[0015] One object of this application is to provide an effective utilization of carbon dioxide contained in flue gas by optimally growing algae in a bioreactor system.

[0016] Another object of this application is to utilize the countercurrent kinetics between the algae fluid and carbon dioxide in order to design sufficient gas residence time such that the algae can maximize the utilization of the gas in the photobioreactor system. The minimum energy input required to do so can be to utilize the buoyancy of carbon dioxide to drive the gas upward and the downward flow of the algae fluid in the downcomer in the vertical photobioreactor.

[0017] Another object of this application is to provide algae harvesting at or near the bottom of the vertical portion of the bioreactor system.

[0018] One object of this application is to provide a scalable modular bioreactor system.

[0019] Another object of this application is to provide a bioreactor system that can be used on land, in water, in ponds, in the ocean, etc.

[0020] Another object of this application is to provide algae as a useful industrial tool for reducing the carbon footprint and becoming a profit center.

[0021] Of course, other objects, goals and embodiments of this application are disclosed in other areas of the entire specification, claims and drawings. Brief Description of the Drawings

[0022] Figure 1 Shows a non-limiting example of a vertical GEMS photobioreactor module according to some embodiments.

[0023] Figure 2 Shows a non - limiting example of a vertical GEMS photobioreactor module according to some embodiments.

[0024] Figure 3 Shows a non - limiting example of a vertical GEMS photobioreactor system with multiple bioreactors connected together according to some embodiments.

[0025] Figure 4 Shows a non - limiting example of flue gas algae - carbon dioxide separation for a bubbling process and re - distribution to a downcomer according to some embodiments.

[0026] Figure 5 Shows a non - limiting example of an algae harvesting method according to some embodiments.

[0027] Figure 6 Shows a non - limiting example of an algae harvesting method using a Coanda screen according to some embodiments.

[0028] Figure 7 Shows a non - limiting example of an algae harvesting method using a Coanda screen according to some embodiments.

[0029] Figure 8 Shows a non - limiting example of a comparison graph of algae growth between a GEMS photobioreactor and an identical circular tube photobioreactor according to some embodiments.

[0030] Figure 9 Shows a non - limiting example of what is shown according to some embodiments Figure 8 with a graph having linear growth in it.

[0031] Figure 10 Shows a non - limiting example of the growth of thermophilic algae in a 6.6 - inch GEMS photobioreactor compared to growth in a 5.1 - inch diameter circular bubble column according to some embodiments.

[0032] Figure 11 Shows a non - limiting example of a graph showing the effect of helical modification on algae growth according to some embodiments Figure 8 in it.

[0033] Figure 12 Shows a non - limiting example of a photobioreactor system connected to a building according to some embodiments.

[0034] Figure 13 Shows a non - limiting example of the arrangement of many photobioreactor modules according to some embodiments.

[0035] Figure 14Shows a non - limiting example of a filter for separating carbon dioxide from nitrogen according to some embodiments.

[0036] Figure 15 Shows a non - limiting example of a combination of horizontal and vertical GEMS tube systems according to some embodiments.

[0037] Figure 16 Shows a non - limiting example of the integration of a GEMS system in an ethanol - corn - fertilizer - algae industry according to some embodiments.

[0038] Figure 17 Shows a non - limiting example of the integration of a GEMS system in a coal or natural gas - wastewater - algae industry according to some embodiments.

[0039] Figure 18 Shows a non - limiting example of a photograph of an algae - carbon dioxide removal process unit according to some embodiments.

[0040] Figure 19 Shows a non - limiting example of a photograph of an algae dehydration device depending on high streamline curvature and density difference between algae and water according to some embodiments.

[0041] Figure 20 Shows a non - limiting example of a photograph of denser algae settling in a column according to some embodiments.

[0042] Figure 21 Shows a non - limiting example of Asparagopsis algae according to some embodiments.

[0043] Figure 22a Shows a non - limiting example of nodes of electrostatic waves for collecting algae according to some embodiments.

[0044] Figure 22b Shows a non - limiting example of nodes of electrostatic waves and algae sinking according to some embodiments.

[0045] Figure 23 Shows a non - limiting example of three outer towers arranged around a central tower according to some embodiments.

[0046] Figure 24 Shows a non - limiting example of three outer towers arranged around a central tower according to some embodiments.

[0047] Figure 25 Shows a non - limiting example of four outer towers arranged around a central tower according to some embodiments.

[0048] Figure 26 Shows a non - limiting example of four outer towers arranged around a central tower according to some embodiments.

[0049] Figure 27 Illustrates a non - limiting example of four external towers arranged around a central tower according to some embodiments.

[0050] Figure 28 Illustrates a non - limiting example of five external towers arranged around a central tower according to some embodiments.

[0051] Figure 29 Illustrates a non - limiting example of six external towers arranged around a central tower according to some embodiments.

[0052] Figure 30 Illustrates a non - limiting example of a photograph of a vertical GEMS system with wire mesh reinforcement according to some embodiments.

[0053] Figure 31 Illustrates a non - limiting example of a photograph of a lamp used with a reinforced vertical GEMS system according to some embodiments. Detailed Description

[0054] It should be understood that the embodiments include multiple aspects, which can be combined in different ways. The following description is provided to list the elements and describe some embodiments of the present application. These elements are listed with the initial embodiments; however, it should be understood that they can be combined in any way and in any number to produce additional embodiments. The various described examples and preferred embodiments should not be construed as limiting the embodiments of the present application to the explicitly described systems, technologies, and applications. One or more of the illustrated specific embodiments are merely examples. This specification should be understood and intended to support broad claims and each embodiment, even claims that exclude other embodiments. Importantly, the disclosure of only exemplary embodiments does not mean limiting the scope of other more encompassing claims that can be achieved, where such exemplary embodiments may be just one of several methods or embodiments that can be used in broader claims, etc. Additionally, this description should be understood to support and cover all the various embodiments, systems, technologies, methods, devices, and applications of the specification and claims, which have any number of disclosed elements, with each individual element, and also with any and all of the various permutations and combinations of all the elements in the present application or any subsequent application.

[0055] Embodiments of the present application include technologies that can provide the following functions: scalability; driving with compressed air, or even flue gas, or even nitrogen separated from flue gas; growth-promoting hybrid spectrum mixing technology; molecular filtration for carbon dioxide separation; carbon dioxide diversion; possibly introducing carbon dioxide separately to generate buoyancy-induced carbon dioxide countercurrent; algal fluid velocity capable of controlling gas residence time; natural algal coagulation; electrostatic standing wave coagulation enhancement; screening dehydration such as using a Coanda screen; centrifugal force via high streamline curvature algal / water separation and harvesting, phototrophic, mixotrophic or even heterotrophic operations; automatic filling, growth, and even harvesting; modularity; low capital expenditure; low operating costs; low land area; any combination or arrangement thereof; etc.

[0056] Embodiments of the present application can solve the following problems: carbon utilization compared to carbon sequestration; production of negative carbon organic fertilizers for improving agriculture compared to chemical fertilizers; oil for renewable diesel and jet fuel; production of higher value products; production of renewable sugars; any combination or arrangement thereof; etc.

[0057] The growth-promoting hybrid spectrum (“GEMS”) mixing technology can be used with a photobioreactor, such as that discussed in International Publication No. WO2020 / 237103A1 of SolarClean Fuels, LLC, which is hereby incorporated by reference herein. This can include a tube that allows light to pass through to reach the algae contained therein. The tube can have spiral indentations, which can affect the flow of the fluid and the algae through the bioreactor. When the algae move in the photobioreactor, these spiral indentations can be used to allow the algae to have sufficient residence time in the light and dark regions.

[0058] Different from that discussed in WO2020 / 237103A1, embodiments of the present application provide a vertical growth-promoting hybrid spectrum photobioreactor system, which can include but is not limited to combining GEMS mixing motion, using the carbon dioxide concentration from flue gas (or other sources), guiding the carbon dioxide to rise contrary to the downward-flowing algae, providing a countercurrent-controlled residence time for maximum algal utilization of carbon dioxide, providing a reactor driven by air or even flue gas with low power and low shear stress, incorporating nano or microbubbles in the bubbling at the bottom of the downcomer, combining high streamline curvature for dehydration, any arrangement or combination thereof, etc.

[0059] An embodiment may include a photobioreactor system that includes at least one downcomer column having helical indentations configured to provide a growth-promoting mixed spectrum mix therein; a riser column connected to the at least one downcomer column; an algae fluid input configured to input a fluid with algae into the at least one downcomer column near the top of the downcomer column and configured to create a downward algae fluid flow in the downcomer column; a gas input configured to input gas into the riser column near the bottom of the riser column and configured to create a gas upward flow in the riser column to drive the system flow; a carbon dioxide gas input configured to input carbon dioxide into the at least one downcomer column near the bottom of the downcomer column and configured to create a carbon dioxide gas upward flow in the downcomer column; a countercurrent flow created in the downcomer column by the downward algae fluid flow and the carbon dioxide gas upward flow, configured to allow an optimal reaction between the algae and the carbon dioxide; and possibly a collection tank configured to collect mature algae from the downcomer column.

[0060] Other embodiments may include a method of using a photobioreactor, the method including the steps of: providing at least one downcomer column having helical indentations; creating a growth-promoting mixed spectrum mix in the downcomer column having the helical indentations; connecting a riser column to the at least one downcomer column; inputting a fluid with algae into the at least one downcomer column near the top of the downcomer column having the fluid input; creating a downward algae fluid flow in the downcomer column; inputting gas into the riser column near the bottom of the riser column having the gas input; driving the system flow with the gas; creating an upward gas flow in the riser column; inputting carbon dioxide into the at least one downcomer column near the bottom of the downcomer column having the carbon dioxide input; creating a carbon dioxide gas upward flow in the downcomer column; a countercurrent flow formed in the downcomer column by the downward algae fluid flow and the carbon dioxide gas upward flow; optimally reacting the algae and the carbon dioxide in the countercurrent flow; and possibly a collection tank configured to collect mature algae from the downcomer column.

[0061] By Figure 1 and Figure 2It can be understood that a vertically enhanced growth-promoting hybrid spectral photobioreactor system (“VGEMSPBR”) (1) can include three towers, an intermediate riser tower (21) that can be referred to as a central tower, a vertical riser or a draft tube, and two outer towers (22) that can be referred to as downcomers or vertical downcomers. Note that any configuration (intermediate, outer, inner) and any number of towers can be used. The towers can be columns, vertical tubes, structures, risers, etc. The towers (or some or possibly all of the towers and / or tubes in the system) can have helical indentations (211) of GEMS that cause fluid flow. The system can be driven by gravity, buoyancy assistance, carbon dioxide fermentation, gas lift, air, flue gas, nitrogen, using pumps, gas compressors, etc. A gas (23), which may be pure carbon dioxide or a gas with at least some carbon dioxide therein, etc., can be input (18) into the intermediate riser tower, possibly at or near the bottom (24) of the tower, such that the gas can flow upward (20). The gas (23) can be air, flue gas, nitrogen separated from flue gas, gas from a chimney, carbon dioxide from the atmosphere, carbon dioxide gas, etc. The gas can be used as a driving force or a propellant for the bioreactor. Depending on the type of gas, the efficiency of the towers and the system can be improved. For example, if the only available carbon dioxide is from the atmosphere, the towers may need to be taller and the bubbling may be smaller because the starting carbon dioxide may be less and all of it may need to be utilized.

[0062] After flowing through the central riser, the gas (23) can be filtered with a filter (16) such that the filtered gas (e.g., oxygen and nitrogen) can be released (17) into the atmosphere with possible gas release, and the carbon dioxide can be recycled (15) to the outer towers (22) with a possible gas recycling assembly (231) which can be a tube, a pipeline, etc. In some embodiments, the flue gas may not be filtered. In an embodiment, the carbon dioxide gas can be recycled to the bottom (27) of the downcomer tower (22) and flow upward (26). As discussed in more detail herein, the upward flow of the carbon dioxide gas can be used as a countercurrent (230) to the algae moving downward in the downward flow (25) of the fluid in the downcomer. The countercurrent can allow for an optimal reaction between the algae and the carbon dioxide, which can be an appropriate amount of reaction time when mixing the algae and the carbon dioxide. Algae and new nutrient-containing water can be input (10) at or near the top (212) of the tower. As the carbon dioxide interacts with the algae, the carbon dioxide is reduced due to being consumed by the algae. For example, at location (4), there can be about 12% carbon dioxide in the fluid, at location (3), there can be about 6% carbon dioxide in the fluid, and ideally, at location (2), there may be no carbon dioxide in the fluid.

[0063] Figure 2Another example of the VGEMS PBR is provided, including but not limited to: input of fluids, algae, and even nutrients (29); a transparent polyethylene tube (33) with a diameter of 6.6 inches (but any size can be used) has been tested; GEMS spiral indentations (34) that can circulate algae in and out of the light area and accelerate algae growth; carbon dioxide input (35); a low-pressure compressed air supply (37) that is directed upward as the system flow (250) along the central riser to drive the circulation of the system; an upward air flow (38) that can provide buoyancy-driven recirculation (30) of algae and nutrients to the external tower; an interaction area (39) between algae and gas; a bubbler (5) that can generate small bubbles such as in the size of nanobubbles or microbubbles; gas release (32) of nitrogen, oxygen, etc.; a defoaming tube (31) that can discharge the released gas and foam (if formed); etc. The height (28) of the tower can be changed. A 17-foot-high tower has been tested, but the optimal height will depend on the algae, the total flow rate, the introduced gas, and the bubble size. Figure 3 , Figure 18 , Figure 30 and Figure 31 illustrate non-limiting examples of the constructed VGEMS PBR system.

[0064] Figure 4 Illustrate non-limiting examples of recirculation in the VGEMS PBR system. The top parts of the intermediate tower (21) and two external towers (22) are shown. Unharvested algae and fluid can be recirculated (54) from the intermediate tower to the external towers. CO2 adsorption liquid and / or defoaming liquid (52) can be stored in a trap (53). Gas (51), such as air, flue gas, nitrogen, oxygen, trace gases, etc., can be contained in the tubes at the top of the VGEMS PBR system. Here, the treated foam (50) can be allowed to defoam and dissolve back into the fluid. A valve (53) can be provided to purge the liquid stored in the trap for reprocessing (if it is an amine) or recirculation. Carbon dioxide can be filtered with a filter (49) so that nitrogen, oxygen, trace gases, any combination thereof, etc. (46) can be released, and carbon dioxide (55) can be recirculated (48) with a recirculation component to the bubbler, compressor, or tank, etc.

[0065] As described herein, embodiments can provide a bioreactor that can be driven by flue gas that may be from a chimney. Some flue gas can be about 85% to about 90% nitrogen and about 10% to 12% carbon dioxide. Most of the oxygen in the flue gas may have been burned in the chimney. The flue gas can be input into a photobioreactor in a central tower. In some embodiments, the flue gas or air can be used directly, and in other embodiments, it can be filtered to possibly separate the nitrogen from the carbon dioxide in the flue gas, as nitrogen may not be necessary and may unnecessarily occupy volume in the system. Certain types of algae may be able to utilize unfiltered flue gas or air, such as extremophile algae. Figure 14 A type of filter, namely a graphene filter (91), is shown, which has carbon dioxide selective polymer chains anchored to the graphene, and the graphene can absorb carbon dioxide from the flue gas. Flue gas (92) having a gas mixture such as nitrogen, carbon dioxide, heavy metals, oxygen, etc. can pass through the filter to separate out carbon dioxide (93). When the flue gas passes through the filter, nitrogen cannot pass through, but carbon dioxide can pass through. The filter can be located at or near the top of the VGEMS PBR, or even at the central riser tower. Optionally, a filter such as a MOF filter can be located in the center, and appropriate pipe and pump systems must be added to the VGEMS PBR array. The filtered carbon dioxide can be transported through a pipe to an external downcomer tower, and may also be transported to the bottom of the tower so that it can infiltrate upward into the external tower. The filtered nitrogen and any remaining oxygen can be released into the atmosphere, or collected, compressed, and used as a driving gas in some VGEMS PBRs.

[0066] Any kind of filter, membrane, molecular filter, metal-oxide framework filter, etc. can be used, which can be located anywhere in the system, and one or more filters can be used. In some embodiments, a single carbon dioxide filter can be used with more than one photobioreactor that may be located in the center. In an embodiment, a high-performance membrane can be used. This type of membrane can be environmentally friendly, produce no waste, can enhance chemical processes, and can even be used in a decentralized manner. The membrane can be based on single-layer graphene having a selective layer thinner than 20 nm, and can have highly tunable chemical properties. In past membranes, there could be more than 1000 gas permeation units (GPU), and could have a carbon dioxide / nitrogen separation factor of more than 20, which can be a measure of its carbon capture specificity. A newer membrane with a separation factor of 22.5 can have a carbon dioxide permeability six times higher at about 6,180 GPU. When optimizing the graphene porosity, pore size, and even functional groups (e.g., chemical groups that actually react with carbon dioxide), an increase in GPU of up to 11,790 can be achieved.

[0067] As described above, carbon dioxide or a gas containing carbon dioxide can be introduced (27) at or near the bottom of each of the two outer towers into a bubbler to provide an upward flow of gas (26) (which is in countercurrent (230) with the algae) (since the algae flow downward and the carbon dioxide can flow upward). The bubbler, which can be a fine mesh disk, a microbubble generator, a nanobubble generator, etc., may have sensors and can be located at the carbon dioxide inlet (27), where the carbon dioxide can be forced through the disk to provide fine bubbles. The carbon dioxide bubbles can rise as a gas to the tower because it can be lighter than the liquid surrounding it and thus can create an upward flow rate. The algae in the liquid can be located in the tower and can have a downward flow (25) in each of the outer towers. This downward flow can resist the upward flow of carbon dioxide. The downward flow can be regulated and can keep the carbon dioxide bubbles near the middle of the tower, perhaps because the bubbles cannot rise faster than the downward fluid opposing them. This can be an indication of countercurrent flow. In a downcomer tower, the upward speed of the carbon dioxide is moderated by the downward flow, which may have a downward fluid flow rate regulator (232) (which can be regulated by the force of the downward flow), so that the algae have time to react with the carbon dioxide bubbles and consume the carbon dioxide bubbles. In some cases, the carbon dioxide may never reach the top of the tower. This can be an optimal condition. In other cases, any remaining carbon dioxide can be recycled, for example, by recycling it to an external GEMS tower where the CO2 can be utilized. The algae can be allowed to have sufficient residence time in the tower to use substantially all of the carbon dioxide and provide an efficient carbon dioxide utilization system. This is especially true if the retained bubble size is kept small and may even need to be in the nanobubble size range. In past horizontal systems, the carbon dioxide bubbles could float to the top of the tube, could form a carbon dioxide cloud, and be pushed along with the liquid, causing excess carbon dioxide to be emitted into the atmosphere, which may be undesirable; however, using countercurrent kinetics with carbon dioxide in a vertical photobioreactor can provide for most of the growing algae to be exposed to a carbon dioxide countercurrent for most of their lifespan, enabling the algae to utilize the carbon dioxide to the maximum extent.

[0068] As the algae flow through the GEMS photobioreactor, they may encounter a dark phase and a light phase as they move between the middle and the outside of the tower GEMS tube. The system can include a cross-flow time scale, where the algae can be moved between the light and dark zones. This can be regulated according to the type of algae used, the average flow rate, and the depth and pitch of the GEMS spiral. Controlling the light / dark cycle by the depth and pitch of the spiral indentation and the average flow rate can result in the fastest algae growth and the fastest carbon dioxide utilization in the presence of optimal carbon dioxide and nutrients.

[0069] As discussed above, a bubbler may be included in the VGEMS PRB system to generate bubbles, such as carbon dioxide bubbles. Algae can extract more carbon dioxide in a system with smaller bubble sizes. It may be desirable to provide a system that utilizes all or substantially all of the carbon dioxide that algae can use during their contact time with carbon dioxide. It may also be desirable to introduce only enough carbon dioxide into the downcomer such that the algae therein can utilize it. If the algae do not utilize all of the carbon dioxide, the carbon dioxide may return to the atmosphere at the top of the VGEMS PBR tower or be recaptured and recycled as described above.

[0070] The bubble size can be in the range of millimeters, micrometers, and nanometers. For carbon dioxide utilization by algae in the downcomer, it may be desirable to use the smallest bubble size, which can be consistent with fully utilizing the carbon dioxide introduced into the downcomer during the contact time with the algae. Due to the countercurrent interaction between the algae and carbon dioxide in the downcomer, an optimal contact time can be utilized. The bubble size can provide a bubble rise time, and the opposing downward flow rate can be adjusted such that the carbon dioxide can interact with the algae. For crossflow motion in the tubes of the VGEMS PBR, there may be an optimal velocity range, so the bubble rise velocity may need to be slightly greater than the downward flow, and the bubble size may need to be optimized such that all or substantially all of the carbon dioxide is utilized before reaching the top of the downcomer. The optimal countercurrent velocity can be a function of the bubble size and even the characteristics of the algae.

[0071] In an embodiment, nanobubbles can be used in the downcomer, and the nanobubbles can be introduced in a volume such that the GEMS motion can distribute the bubbles and the carbon dioxide they carry to all of the algae in the downcomer that may need carbon within a given time. In an embodiment, microbubbles or even nanobubbles may not be required in the riser, but they can be used in certain gas mixture situations.

[0072] The VGEMS PBR countercurrent aspect can provide further potential for engineering optimization. For example, if smaller bubbles are used, the height of the downcomer required can be shorter and still be able to fully utilize the carbon dioxide by the algae. This can result in lower greenhouse costs, lower pressure at the bottom of the VGEMS tower, and even the use of less robust (e.g., lower cost) materials. Part of the balance may involve the higher cost of a smaller nanobubble size production device and the additional expenses required for temperature control.

[0073] Embodiments can provide other ways to increase the algae growth rate and optimal carbon dioxide adsorption. This can include microbubble bubbling devices, pulsed bubble generation, and countercurrent carbon dioxide and algae flow, increased residence time, any combination thereof, etc., as may be discussed herein in the downcomer piping.

[0074] Figures 8 to 11 Provide the graphical results of an algal growth comparison experiment between a vertical GEMS photobioreactor and a circular tube photobioreactor. The PBR is a 3-tower vertical circular tube PBR with tubes of the same diameter and height, but without GEMS improvements. It is identical to the VGEMS system; having the same dimensions, flow rate, countercurrent velocity, and bubbling, the same upper and lower manifolds, it uses the same algae, nutrients, driving air, and CO2 input, but is not the improved GEMS. Figure 8 Show the growth of algae in the vertical GEMS photobioreactor (75) and the growth of algae in the circular tube photobioreactor (76). As Figure 9 shown, the results of the VGEMS PBR provide an initial linear growth rate (77). A new, better linear growth rate (78) forms in the later stage of the experiment. Here, the cyanobacterium (PCC11901) grown in the 4.5" diameter vertical GEMS PBR tube shows a growth rate (78) that is faster than the initial linear growth rate (77) and faster than the horizontal circular tube growth. This seems to be due to the optimization of the light and dark cycles in the vertical GEMS PBR tube. In the circular tube, as the algae become dense, the algal growth rate slows to zero (79).

[0075] Figure 10 Provide another example using the thermophilic red alga C. merolae. Again, a second linear growth rate (80) forms in the vertical GEMS PBR. Its growth rate is slower than the initial growth rate. However, compared to the growth of algae in the circular tube (81), the growth in the vertical GEMS PBR lasts for almost twice the growth period. The vertical GEMS PBR can produce algae with twice the density for harvesting after about 60 days (note that the experiment here was stopped after 48 days and then restarted). In this experiment, the thermophilic C. merolae was grown in a 6.625-inch diameter VGEMS PBR tube and compared with data from growth in a 5.1-inch diameter circular tube bubble column.

[0076] In an embodiment, the light / dark cycle can be adjusted for each specific type of algae to result in a growth rate higher than that obtained with the initial linear growth rate. This can be achieved by adjusting the depth of the helical indentation with a helical indentation regulator (233) and even adjusting the flow rate of a specific alga. Thus, the crossflow velocity can be adjusted, and thus the time for the algae to move across the tube to see the light at the wall can be adjusted. Figure 11Different growth rates were compared with a hypothesized faster growth rate. After a period of time, the algae growing in the circular tube reduced its growth rate to zero (82). The algae growing in a tube with a helical indentation of approximately 0.3 radius can have the growth rate shown (83). The algae growing in a tube with a helical indentation of approximately 0.44 radius (depth of the helical indentation compared to the radius of the tube) can have the growth rate shown (84). A hypothesized growth rate is assumed for the algae growing in a tube with a helical indentation of approximately 0.55 radius (85). As the helical indentation becomes deeper, the algae growth rate appears to increase. Therefore, optimizing the depth of the helix can be advantageous in optimizing these systems.

[0077] The vertical GEMS PBR system can provide special effects that enable better algae harvesting. When the algae flow down along the downcomer, some condensation may occur, and if the algae clumps are heavier than water, the algae (135) will deposit in the collection section at the bottom as shown in Figure 20 Additional electrostatic standing wave condensation as shown in Figure 22a and Figure 22b can be induced. Therefore, as shown in Figure 22a and Figure 22b , the initial condensation can be enhanced at the nodes of the electrostatic wave. The standing wave can be generated by electrostatic forces. The algae can be collected and condensed in the nodes of the standing wave.

[0078] When harvesting the growing algae descending along the downcomer, the Coanda effect, gravity, or even centrifugal force can be utilized to separate the algae from the water. Figure 5 Non - limiting examples of collecting algae near the bottom (200) of the downcomer tower are provided. The algae and fluid can move downward (58) in the downcomer. A positive charge plate (57) and a negative charge plate (56) connected to the system can be used to condense the algae with an algae condenser that may be located near the bottom of the downcomer tower. The Coanda sieve (61) can be used in the downcomer so that larger mature algae and algae clumps (59) are guided and fall around the side (60) of the Coanda sieve into the collection tank (64). Smaller algae and fluid can pass through (62) the sieve and flow (163) through the highly streamlined curvature (161) in the tube, where the fluid and smaller algae can be recycled (63) through the system. Valves that can be automatically operated can be opened and closed to collect the algae in the collection tank. For example, valve (65) can be closed and valve (66) can be opened to harvest the algae (64) from the collection tank (64).

[0079] More specifically, the curved streamlines of the VGEMS PBR system can be used to harvest algae. The inertia of heavier, larger, and more mature algae particles can keep them moving in the current direction (such as in a straight line or on a line that is straighter than the streamlines formed in the overall VGEMS PBR geometry). Other less dense particles, such as lighter algae, fluid, and nutrients, can flow along the streamline curves, where they can be recycled in the system. Gravity and the high streamline curvature (161) in the tubes can contribute to continuous algae harvesting. Algae can be denser than water, so that when the vapor stream of the algae and water mixture reaches a high streamline curvature in the tube, the algae and the heavier algae can not follow the fluid direction (74) of the streamline curvature and can fall to the bottom of the tower, while the fluid can follow the curvature and separate the algae particles, as Figure 7 shown. Figure 19 A non-limiting example of a photograph showing the high curvature in the tubes of a vertical GEMS PBR system is provided, which can provide a high-curvature flow (74) and is capable of harvesting the growing algae. A non-limiting example of using PVC tubes is used here to provide the curved streamline effect. This geometry positions the algae below the level required to turn into the riser tube and then forces them to continue upward through their circulation path to the riser tube. This manifold is constructed of off-the-shelf 6” diameter PVC components and has a 135-degree bend at the elbow. The liquid flow can descend downward from two external downcomers, can be accelerated by the area contraction, and then can flow upward to the central riser tube to complete the loop. The algae in the flow will have to bend around the 135-degree streamline curvature. The system can be designed with tubes of any size and bends of any shape to optimize the harvesting of the growing algae. The inner diameter at the bend can be adjusted to reduce the shear effect. The algae that cannot make the turn can fall into the collection area (see arrow).

[0080] It may be necessary to optimize the flow dynamics so that the mature, heavier algae do not rotate and thus move downward into the collection area. These parameters can include the combination of the average flow velocity in the downcomer and the radial velocity of the average streamline returning to the bend generated by the curvature of the streamline at the bend. The system can be customized with a custom mold, and in this way, the radius of curvature of the bend can be customized. It may be necessary to evaluate a wide range of flow velocities in creating a custom system for different types of algae, including but not limited to microbubble size, countercurrent dynamics, degree of bend, freedom of area ratio in the bend, etc. The instantaneous velocity can determine the final trajectory of any algae cell, so it can make multiple cycles around the VGEMS PBR before the algae cell (even a mature cell) can fall into the collection area and be harvested. The final custom configuration can be determined by trial and error, but the same concept can be embodied in all subsequent configurations.

[0081] Based on the toughness and density differences of the cell walls and even the size of the algal cells, separation of the fluid and water from the algal cells can be achieved. The algal filter and dehydrator can be configured to potentially filter and remove water from the mature algae using the Coanda effect. Figure 6 The arrangement of a Coanda sieve (61) is shown. The Coanda sieve or other types of filters can be in the shape of a bell curve, which can direct the fluid flow (67) from the upstream pool (68). It can include an acceleration plate (69) and a wedge wire screen (70), perhaps similar to teeth. The Coanda effect (71) can keep the flow attached to the top surface of each screen. The inclined wires can shear the flow passing through the sieve. The diversion (72) and bypass flow (73) are shown. When the fluid flow and algae pass through the sieve, the fluid can flow through and even flow around the corners and back into the bioreactor, but the condensed algae can be collected near the bottom for harvesting. The sieve can allow small algae and water to pass through the sieve (perhaps for further growth), but can deflect larger algal clumps around its sides for collection into a collection tank. The smaller algae can move within the tower and can be recycled. In the absence of a sieve, all the algae in the tower can continue to be recycled, and it may be difficult to concentrate them for harvesting. With a filter or sieve, larger algal clumps can be separated. It is easier to collect the algae with a sieve because the algae may not have as much water. In an embodiment, the algasiphonia algae (136) shown in Figure 21 can be separated using a Coanda sieve. Of course, a combination of physical effects can be utilized to optimize dehydration and harvesting, such as a continuous system of Coanda sieves and high-curvature centrifugal dehydration, which can complement each other.

[0082] The system can be modular and scalable. Modularity can enable the bioreactor system to grow organically. Due to a large number of modules, maintaining any module in the system may not actually interrupt the entire operation. Scalability can enable the bioreactor system to meet individual needs that may be large-scale or even small-scale.

[0083] Figure 3 A non-limiting example of a vertical GEMS photobioreactor system with multiple VGEMS PBRs (1) connected together is shown. These figures show a schematic diagram of the tubes that can be used to automatically refill and empty the connected VGEMS photobioreactors (42). The input (10) of materials can flow into (43) the system via a single tube or multiple tubes. Such input can include fluid, algae, algal reserves, nutrients, any combination thereof, etc. Then this input can flow into (44) each VGEMS PBR unit, where, Figure 3Five units are shown, however any number of reactors can be combined. Separate operation controls (which can be automated) can be used to control each bioreactor individually, can respond to sensor inputs from each separate system, and can utilize multiple valves in each system to control valve inputs (40) and valve outputs (41). When ready, mature algae and fluid can be output from each bioreactor via output (11). (The geometries of the aforementioned Coanda and high curvature dehydration devices are not shown in the schematic.) Then, new inputs of fluid, algae stock, nutrients, etc. can be refilled and input into each bioreactor, and algae can be produced when the ready algae and fluid can be output again. Some algae can be retained in the system to seed new algae production. This cycle can be refilled and emptied as needed multiple times. Since it can be managed by sensors, the operation can be fully computer controlled. The sensors can indicate that one or more modules are ready to be harvested at any given time, although the figures can indicate that the 5 modules shown are being harvested simultaneously. In an embodiment, part or even the entire system can be automated.

[0084] The system can be scaled up by making the tubes larger and replicating to a large system. In some embodiments, the modular system can be incrementally increased as needed. For example, a user can start with 5 VGEMS PBRs, and then as the company grows, about 5 or more can be added, etc. Each VGEMS PBR can have a different size, such as using larger tubes, longer tubes, smaller tubes, shorter tubes, etc. As the VGEMS PBR system gets larger, the total capital expenditure can become less, especially using flexible plastics, and further due to requiring fewer valves, less leakage, etc. for a given volume.

[0085] The VGEMS PBR system can be added to an existing building (87), as Figure 12 shown by the non - limiting example of. The new system (88) can be connected to one side of the building in a single - layer connected VGEMS PBR (86). Each bioreactor can be connected to form a configuration. For example, a stack can have 6 VGEMS PBRs; however, any configuration can be used with any number of bioreactors. The type of system can be based on the type of algae, the amount of available carbon dioxide, the amount of available wastewater, lighting arrangements, etc. One side of the building with VGEMS PBRs can be the south side that utilizes sunlight. The modularity of the system can allow for multifunctional use to suit the users and their needs. Figure 13A non-limiting example of the arrangement of a 380V GEMS PBR module with 4 downcomers and one riser is shown. Depending on the size of the module and system, this can be placed in a building on half an acre, etc. Each VGEMS PBR (86) can be arranged (89) in the building. They can be organized in rows and columns, and the rows can be spaced a certain distance apart (90), such as about 6 feet apart, for fire protection and maintenance.

[0086] As mentioned herein, embodiments of the present application can include a system having valves (such as solenoid valves) that can be automatically operated with a computer program, possibly opening and closing the valves. The valves can be included in each VGEMS PBR module, in each column of each module, and connected in an array of modules. The valves can assist in filling and emptying the reactors, whether it is for one VGEMS PBR or for multiple reactors in a number from about 5 to about 500 or more. Valves that can be computer-controlled can be located at the top of the vertical bioreactor system, and another valve can possibly be located at the bottom. A pressurized supply line input can supply nutrients and possibly algal feedstock, etc. to the system as needed. The output line can be a suction line for withdrawing the algae when it is mature and even ready to be harvested. The bioreactor can be emptied individually, or if connected to other bioreactors, it can be emptied together, or the system can pick and choose when to empty what bioreactor at different times. The input portion, which can be a pipe, can be under pressure and filled with nutrients, but in some cases, it cannot be input into the bioreactor until the valve can be opened. To fill an empty reactor, the top valve can be opened and the bottom valve can be closed. There may be some gas that needs to be released. Once the VGEMS PBR is possibly full, the algae can cycle and grow, and possibly after a period of time (e.g., about 5 days, about 10 days, depending on the type of algae, which can be any possible time), it can be emptied. Once emptied, the VGEMS PBR can be cleaned and refilled to start a new cycle. Sensors in the system can provide data so that the system can automatically determine when the bioreactor needs to be filled, emptied, etc. In addition, embodiments can provide an automated system where the harvesting and intermittent refilling of the bioreactor can be continuous.

[0087] Embodiments can provide a VGEMS PBR system, which can be located on land, in the ocean, on water, in bays, cooling ponds of power plants, etc. In water, such as in the ocean, the system can be tethered to structures such as windmills, the seabed, etc. In the ocean, the temperature of the ocean can be used to regulate the temperature of the VGEMS PBR. In some embodiments, about one-third (or more or less) of the bioreactor can float above the sea line and be exposed to sunlight (which can be regulated using floats). In some cases, mixotrophic algae can be used, which can grow in both darkness and light and can be mixed between the light and dark regions of the reactor. The VGEMS PBR system can be located near coal-fired power plants, wastewater treatment plants, etc., and can utilize the carbon dioxide waste and / or wastewater from them, as discussed in more detail herein. In an embodiment, the bioreactor can float in water or in a cooling pond to avoid occupying land space. Such a system can be a closed-loop and can avoid additional construction costs.

[0088] Possibly due to the vertical nature of some systems, embodiments can provide increased algae production per acre. Conventional algae growth systems that occur in ponds can be merely horizontal systems. Some algae can survive on very little carbon dioxide and can live for long periods, where carbon dioxide from the air can be sufficient to support the system. Such a system can be effective in a direct air capture system or can be used in combination with other direct air capture systems that can concentrate carbon dioxide.

[0089] In an embodiment, the photobioreactor system can include a combination of a vertical tube system and a horizontal tube system, as Figure 15 shown in the top view of the system. The horizontal system can be understood in WO2020 / 237103A1. A combination of vertical risers and downcomers or horizontal GEMS tubes and vertical GEMS tubes can be used in various systems. Figure 15 Four VGEMS PBR modules (95) connected to a horizontal tube (94) are shown. By including a horizontal PBR in the system, lower costs can be achieved as long as there is sufficient space to include the horizontal PBR section. The horizontal portion of the system may require one of a variety of possible means to enable gas and fluid to move along the tube (96). This can be achieved by connecting short sections of a helix with spacers, using short sections of various connectors that allow gas to pass through, squeezing the helix in some places to allow gas to pass through, etc.

[0090] In an embodiment, direct air capture can utilize filters to separate carbon dioxide from the atmosphere, concentrate the carbon dioxide, and the concentrated carbon dioxide can be used to grow algae faster. In this type of application, although any configuration can be used, each riser can use 4 to 6 downcomers. Maximizing countercurrent mass may be desirable. The riser used for this purpose need not be a GEMS riser, since compressed air will be the driving gas, but GEMS can be used.

[0091] Risers, downcomers, their tubes and pipes can be made of plastic materials. The breaking strength, tensile strength and transparency of the catalytic mixture of LLDPE and metallocene and other catalysts need to be continuously checked to improve the combination of materials used in the tubes. Its construction can include a method for laying a helix; the slope of the ground may be related to the depth of the helix to facilitate gas passage; and if a rigid tube is required for the application, the helical grooves can be indented during the extrusion of the tube with a ball bearing race and bolted to the extruder; etc. For soft plastics, a mesh cover can be used, which can expand the range of plastics that can be used. As a non-limiting example, metallocene-catalyzed linear low-density polyethylene provides a wide range of properties. The correct combination of flexible plastic tensile strength, secant modulus, mesh size, mesh material, mesh material strength and VGEMS liquid height can enable inexpensive plastics (relative to rigid tubes) to be used in many cases.

[0092] In an embodiment, the system can be designed based on the algae used and even the industrial environment. A bioreactor system and even its configuration can be constructed to accommodate the rate of the effluent stream to be treated and even the speed at which the algae can move without being damaged due to the higher speed in the central riser tower. For example, the larger the diameter of the central tower, the slower the algae can move in the riser, while still having the necessary speed in the outer tower, which can be a downcomer, around it to optimize the absorption of CO2 by the algae. Thus, in an embodiment, the vertical bioreactor system can adopt any different configurations, including but not limited to having a single riser tower with one, two, three, four, five, six, seven, eight, nine, ten or more downcomer towers, as can be understood from Figures 23 to 29 this. This can be determined by the type of algae used and the application used. For any configuration of the downcomer (138), the central riser tower (137) can have a smaller or even larger diameter, which may depend on the available energy input and even on the speed at which the algae can be processed.

[0093] Embodiments can include the integration of the VGEMS PBR system with other industries. Figure 16 An integrated ethanol-corn-fertilizer-algae system is shown, and Figure 17An integrated coal or natural gas - wastewater - algae system is shown. In Figure 16 , a cornfield (102) can be used to grow food and fuel and can utilize carbon dioxide (99) and water (101). Of course, other crops can be substituted. A fertilizer plant (98) can convert methane (97) into ammonia and nitrogen (100), and the nitrogen can be absorbed by the cornfield, and this reaction can release carbon dioxide (112) from the equipment. These carbon dioxide emissions (112) can be supplied to an algal photobioreactor system (210). Corn (103) can be harvested from the field and processed at an ethanol plant (104) to provide ethanol (105), cattle feed (106), and even (107) renewable jet fuel. The ethanol plant can also generate carbon dioxide emissions (110), distillers' grains wastewater (109), and even waste heat (108), which can be input into the algal photobioreactor system (210). The fertilizer used in the cornfield can provide high ammonium runoff (111), which can be supplied to the algae in the photobioreactor system (210) to help them grow. The algal photobioreactor system (210) can include a VGEMS PBR (113), horizontal photobioreactors (114) with and without GEMS, and any combination or arrangement thereof. The photobioreactor system (210) can produce: oil (115), which can be used for renewable jet sustainable aviation fuel (121); nutrients (116), which can be used for ω3 and ω6 supplements (122); organic fertilizer (117), which can be used with organic products (123); astaxanthin (118), which can be used with human antioxidants (124); protein (119), which can be used for cattle, fish, etc. (125); and possibly even phycocyanin (120), which can be used for humans and food (126).

[0094] In Figure 17 , a wastewater treatment plant (127) can provide water (128), and the water (128) can be supplied to a coal or natural gas power plant (129) to generate electricity (130). The wastewater treatment plant can produce an effluent (131) with phosphates and nitrates that can be supplied to the photobioreactor system (210). Carbon dioxide (132), electricity (133), and possibly even waste heat (134) can be generated by the power plant and supplied to the photobioreactor system (210). As Figure 16 discussed, the photobioreactor system can utilize algae with PBRs to produce many reusable products while using carbon dioxide emissions and other wastes from commercial processes to fuel the photobioreactor system.

[0095] Although the present invention has been described in connection with some embodiments, the present invention is not intended to limit the scope of the present application to the specific forms set forth, but on the contrary, the present invention is intended to cover such alternatives, modifications and equivalents that may be included within the spirit and scope of the present application. Examples of alternative claims may include:

[0096] 1. A photobioreactor system, comprising:

[0097] At least one downcomer column having helical indentations configured to provide a growth-promoting mixed spectrum mixture within the downcomer column;

[0098] A riser column connected to the at least one downcomer column;

[0099] An algae fluid input configured to input a fluid having algae into the at least one downcomer column near the top of the downcomer column and configured to create a downward algae fluid flow within the downcomer column;

[0100] A gas input configured to input gas into the riser column near the bottom of the riser column and configured to create an upward gas flow within the riser column to drive the system flow;

[0101] A carbon dioxide gas input configured to input carbon dioxide into the at least one downcomer column near the bottom of the downcomer column and configured to create an upward carbon dioxide gas flow within the downcomer column;

[0102] A countercurrent flow created within the downcomer column by the downward algae fluid flow and the upward carbon dioxide gas flow, configured to allow an optimal reaction between the algae and the carbon dioxide; and

[0103] A collection tank configured to collect mature algae from the downcomer column.

[0104] 2. The system according to clause 1 or any other clause, wherein the optimal reaction between the algae and the carbon dioxide includes an appropriate amount of reaction time when the algae and the carbon dioxide are mixed.

[0105] 3. The system according to clause 1 or any other clause, wherein the at least one downcomer column includes at least two downcomer columns.

[0106] 4. The system according to clause 3 or any other clause, wherein the at least two downcomer columns are each located outside the riser column.

[0107] 5. The system as described in clause 1 or any other clause, wherein the riser tower comprises the helical indentations, which are configured to provide the growth-promoting hybrid spectral mixing in the riser tower.

[0108] 6. The system as described in clause 1 or any other clause, and further comprising a bubbler, which is near the carbon dioxide gas input and near the bottom of the downcomer tower, and is configured to generate bubbles with the carbon dioxide gas.

[0109] 7. The system as described in clause 4 or any other clause, wherein the bubbles include bubble sizes selected from nano-bubble size and micro-bubble size.

[0110] 8. The system as described in clause 1 or any other clause, wherein the fluid with the algae comprises nutrients in the fluid.

[0111] 9. The system as described in clause 1 or any other clause, and further comprising a filter, which is located near the top of the riser tower and is configured to filter carbon dioxide from the gas.

[0112] 10. The system as described in clause 9 or any other clause, and further comprising a gas release, which is configured to release other gases filtered from the gas, wherein the other gases are selected from nitrogen, oxygen, trace gases, and any combination thereof.

[0113] 11. The system as described in clause 1 or any other clause, wherein the gas is selected from carbon dioxide, air, flue gas, and gas from a chimney.

[0114] 12. The system as described in clause 9 or any other clause, and further comprising a gas circulation assembly, which is configured to circulate the filtered carbon dioxide to the bottom of the downcomer tower.

[0115] 13. The system as described in clause 1 or any other clause, wherein the countercurrent generated by the downward fluid flow of the algae and the upward flow of the carbon dioxide gas in the downcomer tower is configured to consume the carbon dioxide with the reaction between the algae and the carbon dioxide.

[0116] 14. The system as described in clause 13 or any other clause, wherein the countercurrent generated by the downward fluid flow of the algae and the upward flow of the carbon dioxide gas in the downcomer tower is configured to consume substantially all of the carbon dioxide with the reaction between the algae and the carbon dioxide.

[0117] 15. The system as described in clause 1 or any other clause, wherein the tower is made of a transparent tube.

[0118] 16. A system as described in clause 9 or any other clause, wherein the filter is selected from a graphene filter, a membrane, a molecular filter, and a metal-organic framework filter.

[0119] 17. A system as described in clause 6 or any other clause, wherein the bubbler includes a fine wire mesh, a microbubble generator, or a nanobubble generator.

[0120] 18. A system as described in clause 1 or any other clause, and further comprising a downward fluid flow velocity regulator configured to regulate the velocity of the downward fluid flow in the downcomer tower.

[0121] 19. A system as described in clause 1 or any other clause, and further comprising a spiral indentation regulator configured to regulate the depth of the spiral indentation in the tower.

[0122] 20. A system as described in clause 1 or any other clause, and further comprising an algae filter and a dehydrator near the bottom of the downcomer tower, the algae filter and the dehydrator being configured to filter and remove water from the mature algae in the downcomer tower and direct the filtered mature algae to the collection tank.

[0123] 21. A system as described in clause 1 or any other clause, and further comprising an algae coagulator near the bottom of the downcomer tower, the algae coagulator being configured to coagulate the mature algae in the downcomer tower.

[0124] 22. A system as described in clause 21 or any other clause, wherein the algae coagulator includes a charging plate.

[0125] 23. A system as described in clause 20 or any other clause, wherein the algae filter and the dehydrator include a Coanda sieve.

[0126] 24. A system as described in clause 1 or any other clause, and further comprising a high-curvature flow of the fluid flow in the downcomer, the high-curvature flow being configured to filter out heavier algae from the fluid flow.

[0127] 25. A system as described in clause 1 or any other clause, wherein the riser tower connected to the at least one downcomer tower forms a single photobioreactor system.

[0128] 26. A system as described in clause 25 or any other clause, and further comprising a plurality of single photobioreactor systems connected together.

[0129] 27. The system as described in clause 26 or any other clause, wherein each of the plurality of interconnected single photobioreactor systems utilizes a single algae fluid input and a single mature algae output.

[0130] 28. The system as described in clause 26 or any other clause, and further comprising separate operational controls for each of the single photobioreactor systems when interconnected.

[0131] 29. The system as described in clause 28 or any other clause, wherein the separate operational controls are automatically controlled in response to sensor inputs from each single photobioreactor system.

[0132] 30. The system as described in clause 28 or any other clause, wherein the separate operational controls include controlling valves associated with each of the single photobioreactor systems and are configured to open and close the inputs and outputs of each single photobioreactor system.

[0133] 31. The system as described in clause 25 or any other clause, and further comprising a horizontal tube section having the helical indentations configured to provide the growth - promoting mixed spectrum mixture, the horizontal tube section being connected as part of the single photobioreactor system and configured to grow algae in the horizontal tube system.

[0134] 32. The system as described in clause 1 or any other clause, and further comprising an integrated ethanol - corn - fertilizer - algae system configured to integrate the photobioreactor system with industries selected from fertilizer plants, corn fields, ethanol plants, and any combination thereof.

[0135] 33. The system as described in clause 32 or any other clause, wherein the integrated ethanol - corn - fertilizer - algae system is configured to supply at least one by - product selected from carbon dioxide, ammonium runoff, stillage, and waste heat to the photobioreactor system.

[0136] 34. The system as described in clause 32 or any other clause, wherein the integrated ethanol - corn - fertilizer - algae system is configured to produce at least one product selected from oil, nutrients, organic fertilizers, astaxanthin, protein, and phycocyanin from the photobioreactor system.

[0137] 35. The system according to clause 1 or any other clause, and further comprising an integrated coal or natural gas - wastewater - algae system configured to integrate the photobioreactor system with industries selected from wastewater treatment plants, coal power plants, and natural gas power plants.

[0138] 36. The system as described in clause 35 or any other clause, wherein the integrated coal or natural gas - wastewater - algae system is configured to supply at least one by - product selected from effluent, carbon dioxide, electricity, and wastewater to the photobioreactor system.

[0139] 37. The system as described in clause 36 or any other clause, wherein the integrated coal or natural gas - wastewater - algae system is configured to produce at least one product selected from oil, nutrients, organic fertilizer, astaxanthin, protein, and phycocyanin from the photobioreactor system.

[0140] 38. A method of using a photobioreactor, comprising the steps of:

[0141] Providing at least one downcomer column having spiral indentations;

[0142] Generating a growth - promoting mixed spectral mixture in the downcomer column having the spiral indentations;

[0143] Connecting a riser column to the at least one downcomer column;

[0144] Inputting a fluid having algae near the top of the downcomer column having a fluid input into the at least one downcomer column;

[0145] Generating a downward fluid flow of algae in the downcomer column;

[0146] Inputting a gas near the bottom of the riser column having a gas input into the riser column;

[0147] Driving a system flow with the gas;

[0148] Generating an upward gas flow in the riser column;

[0149] Inputting carbon dioxide near the bottom of the downcomer column having a carbon dioxide input into the at least one downcomer column;

[0150] Generating an upward carbon dioxide gas flow in the downcomer column;

[0151] Forming a counter - current in the downcomer column with the downward fluid flow of algae and the upward carbon dioxide gas flow;

[0152] Reacting the algae and the carbon dioxide optimally in the counter - current; and collecting mature algae from the downcomer column in a collection tank.

[0153] 39. The method as described in clause 38 or any other clause, wherein reacting the algae and the carbon dioxide optimally in the counter - current includes an appropriate amount of reaction time when mixing the algae and the carbon dioxide.

[0154] 40. A method as described in clause 38 or any other clause, wherein the at least one downcomer column includes at least two downcomer columns.

[0155] 41. A method as described in clause 40 or any other clause, wherein each of the at least two downcomer columns is located outside the riser column.

[0156] 42. A method as described in clause 38 or any other clause, and further comprising the step of providing the growth-promoting mixed spectrum mixing in the riser column with the spiral indentations in the riser column.

[0157] 43. A method as described in clause 38 or any other clause, and further comprising the step of generating bubbles with the carbon dioxide gas using a bubbler located near the carbon dioxide gas input.

[0158] 44. A method as described in clause 43 or any other clause, wherein the bubbles include a bubble size selected from a nanobubble size and a microbubble size.

[0159] 45. A method as described in clause 38 or any other clause, wherein the fluid contains nutrients.

[0160] 46. A method as described in clause 45 or any other clause, and further comprising filtering carbon dioxide from the gas using a filter located near the top of the riser column.

[0161] 47. A system as described in clause 46 or any other clause, and further comprising releasing other gases filtered from the gas with gas release, wherein the other gases are selected from nitrogen, oxygen, trace gases, and any combination thereof.

[0162] 48. A method as described in clause 38 or any other clause, wherein the gas is selected from carbon dioxide, air, flue gas, and gas from a chimney.

[0163] 49. A method as described in clause 46 or any other clause, and further comprising circulating the filtered carbon dioxide to the bottom of the downcomer column using a gas circulation assembly.

[0164] 50. A method as described in clause 38 or any other clause, and further comprising consuming the carbon dioxide with the reaction between the algae and the carbon dioxide in the countercurrent flow.

[0165] 51. A method as described in clause 50 or any other clause, and further comprising consuming substantially all of the carbon dioxide with the reaction between the algae and the carbon dioxide in the countercurrent flow.

[0166] 52. A method as described in clause 38 or any other clause, wherein the tower is made of a transparent tube.

[0167] 53. A method as described in clause 46 or any other clause, wherein the filter is selected from a graphene filter, a membrane, a molecular filter, and a metal-organic framework filter.

[0168] 54. A method as described in clause 43 or any other clause, wherein the bubbler comprises a fine wire mesh, a microbubble generator, or a nanobubble generator.

[0169] 55. A method as described in clause 38 or any other clause, and further comprising regulating the velocity of the downward fluid flow in the downcomer tower with a downward fluid velocity regulator.

[0170] 56. A method as described in clause 38 or any other clause, and further comprising regulating the depth of the helical indentation in the tower.

[0171] 57. A method as described in clause 38 or any other clause, and further comprising filtering and dehydrating the mature algae in the downcomer tower with an algae filter and a dehydrator near the bottom of the downcomer tower, and guiding the filtered mature algae to the collection tank.

[0172] 58. A method as described in clause 38 or any other clause, and further comprising coagulating the mature algae in the downcomer tower with an algae coagulator near the bottom of the downcomer tower.

[0173] 59. A method as described in clause 58 or any other clause, wherein the algae coagulator comprises a charging plate.

[0174] 60. A method as described in clause 57 or any other clause, wherein the algae filter and dehydrator comprises a Coanda sieve.

[0175] 61. A method as described in clause 38 or any other clause, and further comprising a high-curvature flow of the fluid flow in the downcomer, which is configured to filter out heavier algae from the fluid flow.

[0176] 62. A method as described in clause 38 or any other clause, wherein the riser tower connected to the at least one downcomer tower produces a single photobioreactor system.

[0177] 63. A method as described in clause 62 or any other clause, and further comprising connecting a plurality of single photobioreactor systems together.

[0178] 64. The method as described in clause 63 or any other clause, wherein each of the connected plurality of single photobioreactor systems utilizes a single algae fluid input and a single mature algae output.

[0179] 65. The method as described in clause 63 or any other clause, and further comprising separate operational control for each of the single photobioreactor systems when connected together.

[0180] 66. The method as described in clause 65 or any other clause, wherein the separate operational control is automatically controlled in response to sensor input from each single photobioreactor system.

[0181] 67. The method as described in clause 65 or any other clause, wherein the separate operational control controls the valves associated with each of the single photobioreactor systems, and controls the opening and closing of the inputs and outputs of each single photobioreactor system.

[0182] 68. The method as described in clause 62 or any other clause, and further comprising providing a horizontal tube section having the spiral indentations to produce the growth-promoting hybrid spectral mixture; connecting the horizontal tube system as part of the single photobioreactor system; and growing algae in the horizontal tube system.

[0183] 69. The method as described in clause 38 or any other clause, and further comprising integrating the photobioreactor system with an industry selected from a fertilizer plant, a corn field, an ethanol plant, and any combination thereof.

[0184] 70. The method as described in clause 69 or any other clause, and further comprising supplying at least one by-product selected from carbon dioxide, ammonium runoff, stillage, and waste heat from the industry to the photobioreactor system.

[0185] 71. The method as described in clause 69 or any other clause, and further comprising producing at least one product selected from oil, nutrients, organic fertilizer, astaxanthin, protein, and phycocyanin from the photobioreactor system.

[0186] 72. The method as described in clause 38 or any other clause, and further comprising integrating the photobioreactor system with an industry selected from a wastewater treatment plant, a coal power plant, and a natural gas power plant.

[0187] 73. The method as described in clause 72 or any other clause, and further comprising supplying at least one by-product selected from effluent, carbon dioxide, electricity, and wastewater from the industry to the photobioreactor system.

[0188] 74. A method as described in clause 72 or any other clause, and further comprising producing at least one product selected from oil, nutrients, organic fertilizers, astaxanthin, protein, and phycocyanin from the photobioreactor system.

[0189] 75. A method as described in clause 57 or any other clause, and further comprising the step of recycling the fluid stream to the top of the downcomer after the mature algae have been filtered.

[0190] 76. A method as described in clause 75 or any other clause, wherein the recycled fluid stream comprises young algae, nutrients, fluid, and any combination thereof.

[0191] It can be readily understood from the foregoing that the basic concepts of the various embodiments of the present invention can be embodied in many ways. It includes both bioreactor technology and the means for implementing a suitable bioreactor. In the present application, the bioreactor technology is part of the result achieved through the various means described and is disclosed as utilized with the inherent steps. They are simply the natural result of utilizing the intended and described means. Additionally, although some means are disclosed, it should be understood that these means not only implement certain methods but can also be varied in many ways. Importantly, with respect to all of the above, all of these aspects should be understood to be covered by the present disclosure.

[0192] The discussion included in this application is intended to serve as a basic description. The reader should be aware that specific discussions may not explicitly describe all possible implementations; many alternatives are implicit. It may also not fully explain the general nature of the various implementations of the invention and may not explicitly show how each feature or element can in fact represent a broader function or multiple alternative or equivalent elements. As an example, degree terms, approximation terms, and / or relative terms may be used. These can include terms such as the words: substantially, about, only, etc. These words and types of words should be understood in their dictionary sense to cover terms of a large or significant amount, quantity, size, etc., as well as terms that cover most but not fully specified amounts. In addition, for this application, if used or when used, degree terms, approximation terms, and / or relative terms should be understood to also cover more precise and even quantitative values, which include various levels of precision and claim possibilities, the claims addressing many quantitative options and alternatives. For example, within the scope of ultimate use, the presence or absence of a substance or condition in a particular input, output, or at a particular stage may be specified as being substantially only x or substantially free of x, as being about the value of x, or such other similar language. Using percentage values as an example, these types of terms should be understood to cover options of percentage values that include 99.5%, 99%, 97%, 95%, 92%, or even 90% of a specified value or relative condition; correspondingly, for values at the other end of the spectrum (e.g., substantially free of x, these should be understood to include options of percentage values that include no more than 0.5%, 1%, 3%, 5%, 8%, or even 10% of a specified value or relative condition, which may be specified either by volume or by weight). In context, those of ordinary skill in the art should understand that these are disclosed and included both in an absolute sense and by comparing the value of one set or type of substance to the value of a second set or type of substance. In addition, these are also implicitly included in this disclosure and should (and are considered to be) understood by those of ordinary skill in the art. When this application is described in terms of a device, each element of the device implicitly performs a function. Device claims can include not only claims directed to the device, but also method or process claims to address the functions of the implementation and the functions performed by each element. Neither the specification nor the terms are intended to limit the scope of the claims that will be included in any subsequent patent application.

[0193] It should also be understood that various changes can be made without departing from the essence of the various embodiments of the present invention. Such changes are also implicitly included in this specification. They still fall within the scope of the various embodiments of the present invention. The broad disclosure covering the shown explicit embodiments, various implicit alternative embodiments, and broad methods or processes, etc. is covered by this disclosure, and the broad disclosure can be relied upon when drafting claims for any subsequent patent application. It should be understood that such language changes and broader or more detailed claims can be completed later (e.g., by any required deadline), or in the case where the applicant subsequently seeks a patent application based on this application. With this understanding, the reader should realize that this disclosure should be understood to support any subsequent filed patent application, the scope of the claims for which can be sought for examination within the applicant's rights and can be designed to generate patents covering multiple aspects of the embodiments of the present invention both independently and as an overall system.

[0194] In addition, each of the various elements of the embodiments and claims of the present invention can also be implemented in a variety of ways. Additionally, when used or implied, an element should be understood to cover both a single and multiple structures (which may or may not be physically connected). The present disclosure should be understood to cover each such variation, whether it is a variation of any apparatus embodiment, a method or process embodiment, or even just a variation of any element of these embodiments. In particular, it should be understood that since the present disclosure relates to the elements of the various embodiments of the present invention, even if only the functions or results are the same, the words of each element can be expressed in equivalent device terms or method terms. These equivalent terms, broader terms, or even more general terms should be considered to be included in the description of each element or action. These terms can be replaced when necessary to clearly indicate the broad scope of protection implicitly given to the embodiments of the present invention. Only as an example, it should be understood that all actions can be represented as a means for performing that action or an element that causes that action. Similarly, each physical element disclosed should be understood to include the disclosure of the action facilitated by that physical element. Regarding this last aspect, only as an instance, the disclosure of "flow" should be understood to include the disclosure of the "flowing" behavior (whether explicitly discussed or not), and conversely, whether the "flowing" behavior is effectively disclosed, such disclosure should be understood to include the disclosure of "flow", and even include "means for flowing". Such changes and replacement terms should be understood to be explicitly included in the specification. Additionally, each such apparatus (whether explicitly described or not) should be understood to include all elements that can perform a given function, and all descriptions of the elements that perform the said function should be understood as non-limiting examples of the means for performing that function. As other non-limiting examples, it should be understood that claim elements can also be represented as any of the following: components, programs, subroutines, logics, or elements that are configured or configured and arranged to provide or even achieve a particular result, use, purpose, situation, function, or operation, or are capable of achieving a particular activity, result, use, purpose, situation, function, or operation. All of these should be understood to be within the scope of the present disclosure and the written description.

[0195] Any patents, publications, or other references mentioned in this patent application are hereby incorporated by reference. Any priority claimed in this application is hereby attached and incorporated by reference. In addition, for each term used, it should be understood that, unless its use in this application is inconsistent with a broadly supported interpretation, the general dictionary definition of each term should be understood to have been incorporated, and all definitions, alternative terms, and synonyms (such as those contained in the second edition of Random House Webster’s Unabridged Dictionary) are hereby incorporated by reference. Finally, all references listed in the following reference list or any other information statement filed with this application are hereby attached and incorporated by reference. However, for each of the above, to the extent that such information or statement incorporated by reference may be considered inconsistent with the patent rights obtained for various embodiments of the present invention, such statement is not considered to have been expressly made by the applicant.

[0196] U.S. Patent

[0197]

[0198] U.S. Patent Application Publication

[0199]

[0200]

[0201] Foreign Patent Application Publication

[0202]

[0203] Non-Patent Literature

[0204]

[0205]

[0206]

[0207]

[0208] Accordingly, the applicant should be understood to be entitled to claim and support claims for embodiments including at least the following: i) each bioreactor device as disclosed and described herein, ii) the related methods as disclosed and described, iii) similar, equivalent and even implicit variations of each of these devices and methods, iv) those alternative designs that achieve each function as shown in the disclosure and description, v) alternative designs and methods that implicitly achieve each function as shown in the disclosure and description, vi) each feature, component and step shown as a separate and independent invention, vii) applications enhanced by the various systems or components disclosed, viii) the resulting products produced by such processes, methods, systems or components, ix) each system, method and element as shown or described in any particular field or apparatus currently applicable, x) methods and apparatuses substantially as described above and with reference to any attached embodiments, xi) apparatuses for performing the methods described herein, which include apparatuses for performing the following steps, xii) various combinations and arrangements of each of the disclosed elements, xiii) each potentially dependent claim or concept depending on each or all of the proposed independent claims or concepts, and xiv) all inventions described herein.

[0209] In addition, with respect to computers and every aspect suitable for programming or other electronic automation, it should be understood that in characterizing these and all other aspects of the various embodiments of the present invention, whether described as a device, capability, element or otherwise, since all of these can be implemented via software, hardware or even firmware architectures, as provided for general-purpose computers, programmed chips or chip sets, ASICs, dedicated controllers, subroutines, logic circuits or other known programmable or circuit-specific architectures. It should be understood that all of these aspects are at least defined by the following architectures, including those well known to those of ordinary skill in the art: hardware circuits, firmware, programmed special components and even general-purpose computers programmed to implement the identified aspects. For such items implemented by programmable features, it should be understood that the applicant is entitled to claim and at least make the following statements regarding the present invention: xv) a process executed by or through a computer, machine or computerized apparatus as described throughout the above discussion, xvi) a programmable device as described throughout the above discussion, xvii) a computer-readable memory encoded with data for guiding a computer, the computer-readable memory including means or elements operative as described throughout the above discussion, xviii) a computer, machine or computing apparatus configured as disclosed and described herein, xix) subroutines, processor logic and / or programs, whether alone or in combination, as disclosed and described herein, xx) a carrier medium carrying computer-readable code for controlling a computer to separately execute each of the independent and combined methods described herein or in any claim, xx) a computer program for separately executing each of the disclosed independent and combined methods, xxii) a computer program containing means for performing all combinations of the disclosed independent and combined steps, xxiii) a storage medium storing each of the disclosed computer programs, xxiv) a signal carrying the disclosed computer program, xxv) a processor for executing instructions to implement the detailed steps and activities, xxvi) a circuit configuration (including configurations of transistors, gates, etc.) for sequentially executing and / or initiating detailed actions, xxvii) a computer-readable medium storing instructions for executing the detailed steps and initiating activities, xxviii) the related methods disclosed and described, xxix) similar, equivalent or even implicit variations of each of these systems and methods, xxx) alternative designs that implement each of the functions as shown and described, xxxi) alternative designs and methods that implicitly implement each of the functions shown and described, xxxii) each feature, component and step shown as a separate and independent invention, and xxxiii) various combinations of the foregoing and any aspects, all of which do not limit additional other aspects.

[0210] For the claims under examination now or subsequently presented, it should be understood that, for practical reasons and to avoid unduly increasing the examination burden, the applicant may at any time present only the original claims or only the original claims with only original dependent claims. The Patent Office and any third party interested in the potential scope of the present or subsequent applications should understand that broader claims may be presented subsequently in this case, in an application claiming the priority of this case, or in any continuation application, regardless of whether any preliminary amendments, other amendments, claim language, or statements of opinion have been filed, and thus no waiver or relinquishment of any potential subject matter is intended during the prosecution of any case. It should be understood that if or when broader claims are presented, this may require a re-evaluation of any relevant prior art that may have been considered at any previous time, as any amendments, claim language, or statements of opinion presented in the present or any subsequent application are considered to have been presented, in part, to avoid such prior art, and these reasons may be overcome by the claims presented later, etc. Both the examiner and anyone interested in the existing or future potential scope of protection, or considering whether there is any waiver or relinquishment of potential scope of protection at any time, should be aware that no such waiver or relinquishment is ever intended or has ever existed in the present or any subsequent application. For example, the limitations set forth in Hakim v. Cannon Avent Group, PLC, 479 F.3d 1313 (Fed. Cir 2007), etc. do not apply to the present invention or any subsequent related subject matter. In addition, it should be understood to meet the degree of support required under the new matter laws, including but not limited to Article 123(2) of the European Patent Convention and 35 USC 132 of the United States Patent Law or other such laws, to permit the addition of any one of the various dependencies or other elements presented under an independent claim or concept as a dependency or element under any other independent claim or concept. At any time when drafting any claim, whether in the present application or in any subsequent application, it should be understood that the applicant has intended to obtain the full and broad scope of protection available under the law. In cases of making non-substantive alternatives, in cases where the applicant has not actually drafted any claim to literally cover any particular embodiment, and in other applicable cases, it should not be understood that the applicant has in any way intended or actually relinquished such scope of protection, as the applicant may simply be unable to foresee all possible events; it should not be reasonably expected that a person skilled in the art would have drafted claims that literally cover such alternative embodiments entirely.

[0211] In addition, according to traditional claim interpretation (including that discussed in MPEP §2111.03), when used in an “open-ended” claim herein, the transitional phrases “comprising,” “including,” “containing,” “characterized by,” and “having” are used. Thus, unless the context requires otherwise, it should be understood that the term “comprise” or its variants such as “comprises” or “comprising,” “include” or its variants such as “includes” or “including,” “contain” or its variants such as “contains” or “containing,” “characterized by” or its variants such as “characterizing by,” “have” or its variants such as “has” or “having” are intended to imply the inclusion of the stated element or step, or group of elements or steps, but not the exclusion of any other element or step, or group of elements or steps. Such terms should be interpreted in their broadest form so as to afford the broadest scope of protection legally permissible to the applicant. The use of the phrase “or any other claim” is for providing support for any claim that references any other claim, such as another dependent claim, another independent claim, a previously listed claim, a subsequently listed claim, etc. As a clear example, if a claim references “claim 9 or any other claim,” etc., it may, if desired, be redrafted to reference claim 1, claim 8, or even claim 11 (if it exists) and still fall within the present disclosure. It should be understood that this phrase also provides support for any combination of elements in a claim and even includes any required appropriate reference basis for certain claim combinations (such as combinations with method, apparatus, process, etc. claims).

[0212] Finally, any claim set forth at any time is hereby incorporated by reference herein as part of the specification of the various embodiments of this application, and the applicant expressly reserves the right to use all or part of the incorporated content of these claims as additional description to support any or all of the claims or any of their elements or components, and as needed, the applicant also expressly reserves the right to move any part or all of the incorporated content of these claims or any of their elements or components from the specification to the claims, or vice versa, to define the subject matter sought to be protected in this application or any subsequent continuation, divisional, or partial continuation application thereof, or to obtain any benefit, fee reduction, or compliance with the patent laws, rules, or regulations of any country or treaty. The content incorporated by reference shall remain in force throughout the examination of this application (including any subsequent continuation, divisional, or partial continuation application thereof) or any reissue or extension thereof.

Claims

1. A photobioreactor system, comprising: At least one downcomer column having a helical indentation configured to provide a growth-promoting mixed spectrum mixing in the downcomer column; A riser column connected to the at least one downcomer column; An algae fluid input configured to input a fluid having algae into the at least one downcomer column near the top of the downcomer column and configured to create a downward algae fluid flow in the downcomer column; A gas input configured to input gas into the riser column near the bottom of the riser column and configured to create a gas upflow in the riser column to drive the system flow; A carbon dioxide gas input configured to input carbon dioxide into the at least one downcomer column near the bottom of the downcomer column and configured to create a carbon dioxide gas upflow in the downcomer column; A countercurrent flow generated in the downcomer column by the downward algae fluid flow and the carbon dioxide gas upflow, configured to allow an optimal reaction between the algae and the carbon dioxide; And A collection tank configured to collect mature algae from the downcomer column.

2. The system of claim 1, wherein the optimal reaction between the algae and the carbon dioxide includes an appropriate amount of reaction time when mixing the algae and the carbon dioxide.

3. The system of claim 1, wherein the at least one downcomer column includes at least two downcomer columns.

4. The system of claim 3, wherein the at least two downcomer columns are each located outside the riser column.

5. The system of claim 1, wherein the riser column contains the helical indentation configured to provide the growth-promoting mixed spectrum mixing in the riser column.

6. The system of claim 1, further comprising a bubbler near the carbon dioxide gas input and near the bottom of the downcomer column and configured to generate bubbles having the carbon dioxide gas.

7. The system of claim 4, wherein the bubbles include a bubble size selected from a nanobubble size and a microbubble size.

8. The system of claim 1, wherein the fluid having the algae contains nutrients in the fluid.

9. The system of claim 1, further comprising a filter located near the top of the riser column and configured to filter carbon dioxide from the gas.

10. The system of claim 9, further comprising a gas release configured to release other gases filtered from the gas, wherein the other gases are selected from nitrogen, oxygen, trace gases, and any combination thereof.

11. The system of claim 1, wherein the gas is selected from carbon dioxide, air, flue gas, and gas from a chimney.

12. The system of claim 9, further comprising a gas circulation assembly configured to circulate the filtered carbon dioxide to the bottom of the downcomer column.

13. The system according to claim 1, wherein the countercurrent flow generated by the downward fluid flow of the algae and the upward flow of the carbon dioxide gas in the downcomer column is configured to consume the carbon dioxide by the reaction between the algae and the carbon dioxide.

14. The system according to claim 13, wherein the countercurrent flow generated by the downward fluid flow of the algae and the upward flow of the carbon dioxide gas in the downcomer column is configured to consume substantially all of the carbon dioxide by the reaction between the algae and the carbon dioxide.

15. The system according to claim 1, wherein the column is made of a transparent tube.

16. The system according to claim 9, wherein the filter is selected from a graphene filter, a membrane, a molecular filter, and a metal-organic framework filter.

17. The system according to claim 6, wherein the bubbler includes a fine wire mesh, a microbubble generator, or a nanobubble generator.

18. The system according to claim 1, and further comprising a downward fluid flow velocity regulator configured to regulate the velocity of the downward fluid flow in the downcomer column.

19. The system according to claim 1, and further comprising a helical indentation regulator configured to regulate the depth of the helical indentation in the column.

20. The system according to claim 1, and further comprising an algae filter and a dehydrator near the bottom of the downcomer column, the algae filter and the dehydrator being configured to filter and remove water from the mature algae in the downcomer column and guide the filtered mature algae to the collection tank.

21. The system according to claim 1, and further comprising an algae coagulator near the bottom of the downcomer column, the algae coagulator being configured to coagulate the mature algae in the downcomer column.

22. The system according to claim 21, wherein the algae coagulator includes a charging plate.

23. The system according to claim 20, wherein the algae filter and the dehydrator include a Coanda screen.

24. The system according to claim 1, and further comprising a high-curvature flow of the fluid flow in the downcomer, the high-curvature flow being configured to filter out heavier algae from the fluid flow.

25. The system according to claim 1, wherein the riser column connected to the at least one downcomer column produces a single photobioreactor system.

26. The system according to claim 25, and further comprising a plurality of single photobioreactor systems connected together.

27. The system according to claim 26, wherein each of the plurality of single photobioreactor systems connected together utilizes a single algae fluid input and a single mature algae output.

28. The system according to claim 26, and further comprising separate operation controls for each of the single photobioreactor systems when connected together.

29. The system according to claim 28, wherein the separate operation controls are automatically controlled in response to sensor inputs from each single photobioreactor system.

30. The system according to claim 28, wherein the individual operation controls include controlling valves associated with each of the single photobioreactor systems and are configured to open and close the inputs and outputs of each single photobioreactor system.

31. The system according to claim 25, and further comprising a horizontal pipe section having the helical indentations configured to provide the growth-promoting mixed spectral mixture, the horizontal pipe section being connected as part of the single photobioreactor system and configured to grow algae in the horizontal pipe system.

32. The system according to claim 1, and further comprising an integrated ethanol - corn - fertilizer - algae system configured to integrate the photobioreactor system with industries selected from fertilizer plants, corn fields, ethanol plants, and any combination thereof.

33. The system according to claim 32, wherein the integrated ethanol - corn - fertilizer - algae system is configured to supply at least one by - product selected from carbon dioxide, ammonium runoff, stillage, and waste heat to the photobioreactor system.

34. The system according to claim 32, wherein the integrated ethanol - corn - fertilizer - algae system is configured to produce at least one product selected from oil, nutrients, organic fertilizers, astaxanthin, protein, and phycocyanin from the photobioreactor system.

35. The system according to claim 1, and further comprising an integrated coal or natural gas - wastewater - algae system configured to integrate the photobioreactor system with industries selected from wastewater treatment plants, coal power plants, and natural gas power plants.

36. The system according to claim 35, wherein the integrated coal or natural gas - wastewater - algae system is configured to supply at least one by - product selected from effluent, carbon dioxide, electricity, and wastewater to the photobioreactor system.

37. The system according to claim 36, wherein the integrated coal or natural gas - wastewater - algae system is configured to produce at least one product selected from oil, nutrients, organic fertilizers, astaxanthin, protein, and phycocyanin from the photobioreactor system.

38. A method of using a photobioreactor, comprising the steps of: providing at least one downcomer column having helical indentations; generating a growth - promoting mixed spectral mixture in the downcomer column having the helical indentations; connecting a riser column to the at least one downcomer column; inputting a fluid having algae near the top of the downcomer column having a fluid input into the at least one downcomer column; generating a downward fluid flow of algae in the downcomer column; inputting a gas near the bottom of the riser column having a gas input into the riser column; driving a system flow with the gas; generating an upward gas flow in the riser column; inputting carbon dioxide near the bottom of the downcomer column having a carbon dioxide input into the at least one downcomer column; generating an upward carbon dioxide gas flow in the downcomer column; forming a counter - current in the downcomer column with the downward fluid flow of algae and the upward carbon dioxide gas flow; Optimize the reaction of the algae and the carbon dioxide in the countercurrent; and Collect the mature algae from the downcomer tower in a collection tank.

39. The method according to claim 38, wherein the optimizing the reaction of the algae and the carbon dioxide in the countercurrent includes an appropriate amount of reaction time when mixing the algae and the carbon dioxide.

40. The method according to claim 38, wherein the at least one downcomer tower includes at least two downcomer towers.

41. The method according to claim 40, wherein the at least two downcomer towers are each located outside the riser tower.

42. The method according to claim 38, and further comprising the step of providing the growth-promoting mixed spectrum mixing in the riser tower with spiral indentations in the riser tower.

43. The method according to claim 38, and further comprising the step of generating bubbles with the carbon dioxide gas using a bubbler located near the carbon dioxide gas input.

44. The method according to claim 43, wherein the bubbles include a bubble size selected from the nano-bubble size and the micro-bubble size.

45. The method according to claim 38, wherein the fluid contains nutrients.

46. The method according to claim 45, and further comprising filtering carbon dioxide from the gas using a filter located near the top of the riser tower.

47. The system according to claim 46, and further comprising releasing other gases filtered from the gas by gas release, wherein the other gases are selected from nitrogen, oxygen, trace gases, and any combination thereof.

48. The method according to claim 38, wherein the gas is selected from carbon dioxide, air, flue gas, and gas from a chimney.

49. The method according to claim 46, and further comprising circulating the filtered carbon dioxide to the bottom of the downcomer tower using a gas circulation assembly.

50. The method according to claim 38, and further comprising consuming the carbon dioxide by the reaction between the algae and the carbon dioxide in the countercurrent.

51. The method according to claim 50, and further comprising consuming substantially all of the carbon dioxide by the reaction between the algae and the carbon dioxide in the countercurrent.

52. The method according to claim 38, wherein the tower is made of a transparent tube.

53. The method according to claim 46, wherein the filter is selected from a graphene filter, a membrane, a molecular filter, and a metal-organic framework filter.

54. The method according to claim 43, wherein the bubbler includes a fine mesh plate, a micro-bubble generator, or a nano-bubble generator.

55. The method according to claim 38, and further comprising regulating the speed of the downward fluid flow in the downcomer tower using a downward fluid flow rate regulator.

56. The method according to claim 38, and further comprising regulating the depth of the spiral indentations in the tower.

57. The method according to claim 38, further comprising filtering and dehydrating the mature algae in the downcomer tower with an algae filter and a dehydrator near the bottom of the downcomer tower, and guiding the filtered mature algae to the collection tank.

58. The method according to claim 38, further comprising coagulating the mature algae in the downcomer tower with an algae coagulator near the bottom of the downcomer tower.

59. The method according to claim 58, wherein the algae coagulator comprises a charging plate.

60. The method according to claim 57, wherein the algae filter and dehydrator comprise a Coanda screen.

61. The method according to claim 38, further comprising a high-curvature flow of the fluid flow in the downcomer, which is configured to filter out heavier algae from the fluid flow.

62. The method according to claim 38, wherein the riser tower connected to the at least one downcomer tower produces a single photobioreactor system.

63. The method according to claim 62, further comprising connecting a plurality of single photobioreactor systems together.

64. The method according to claim 63, wherein each of the connected plurality of single photobioreactor systems utilizes a single algae fluid input and a single mature algae output.

65. The method according to claim 63, further comprising separate operation control for each of the single photobioreactor systems when connected together.

66. The method according to claim 65, wherein the separate operation control is automatically controlled in response to sensor input from each single photobioreactor system.

67. The method according to claim 65, wherein the separate operation control controls the valves associated with each of the single photobioreactor systems, and controls the opening and closing of the inputs and outputs of each single photobioreactor system.

68. The method according to claim 62, further comprising providing a horizontal pipe section with the spiral indentation to produce the growth-promoting hybrid spectrum mixing; connecting the horizontal pipe system as part of the single photobioreactor system; and growing algae in the horizontal pipe system.

69. The method according to claim 38, further comprising integrating the photobioreactor system with an industry selected from a fertilizer plant, a corn field, an ethanol plant, and any combination thereof.

70. The method according to claim 69, further comprising supplying at least one by-product selected from carbon dioxide, ammonium runoff, stillage, and waste heat from the industry to the photobioreactor system.

71. The method according to claim 69, further comprising producing at least one product selected from oil, nutrients, organic fertilizers, astaxanthin, protein, and phycocyanin from the photobioreactor system.

72. The method according to claim 38, further comprising integrating the photobioreactor system with an industry selected from a wastewater treatment plant, a coal power plant, and a natural gas power plant.

73. The method according to claim 72, further comprising supplying at least one by-product selected from effluent, carbon dioxide, electricity, and wastewater from said industry to said photobioreactor system.

74. The method according to claim 72, further comprising producing at least one product selected from oil, nutrients, organic fertilizers, astaxanthin, proteins, and phycocyanin from said photobioreactor system.

75. The method according to claim 57, further comprising the step of recycling said fluid stream to the top of the downcomer after said mature algae have been filtered.

76. The method according to claim 75, wherein said recycled fluid stream comprises young algae, nutrients, fluid, and any combination thereof.

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