Vertical bioreactor technology methods, systems, and processes

Abstract

Embodiments provide a photobioreactor system, such as a vertical growth-enhanced mixed-spectrum photobioreactor (1), including, but not limited to, at least one downcomer tower (22) having a spiral pattern (211), a riser tower (21), an algae-fluid input (10), an algae-downstream fluid flow (25) in the downcomer tower, a gas input (18) for driving system flow (250), a gas-upstream flow (20) in the riser tower, a carbon dioxide gas input (27) having a lower carbon dioxide mass flow than the mass flow in the riser tower, a carbon dioxide gas-upstream flow (26) in the downcomer tower, and a countercurrent flow (230) generated using the algae-downstream fluid flow and the carbon dioxide gas-upstream flow, and possibly a collection tank (64) for dewatered algae. Multiple photobioreactor systems are provided, each of which can be connected and automatically controlled.

Description

[Technical Field]

[0001] This application is a PCT patent application that claims priority to and benefit of U.S. Provisional Patent Application No. 63 / 416,562, filed October 16, 2022, which is incorporated herein by reference in its entirety.

[0002] (Technical field) Embodiments of the present application relate to enhanced growth-enhancing mixed-spectrum ("GEMS") mixing technology involving algae and carbon dioxide utilization. Vertical photobioreactors can be utilized to efficiently grow algae fueled by air or flue gas containing carbon dioxide. A combination of vertical and horizontal tubes may be optimal in some embodiments. [Background technology]

[0003] The power generation industry is under increasing pressure to produce electricity from renewable energy sources. Many biofuels meet renewable energy source standards; however, sources of traditional biofuels, such as biomass, biodiesel, bioethanol, and biogas, may not be geographically uniformly distributed across the country and the world, and these sources may not generally be located near power generation facilities. At the same time, reductions in carbon dioxide and other gas emissions from various sources are becoming increasingly necessary and desirable. In addition, the imposition or even potential imposition of a carbon tax may make carbon capture and utilization even more economically desirable. Typically, capturing carbon dioxide from the flue gases of anthropogenic sources such as power plants and then sequestering it can be expensive, and the long-term outcomes can be uncertain (e.g., the earth may tremble and re-erupt the gas, underground contamination of water supplies, etc.).

[0004] Photosynthesis, on the other hand, is nature's way of recycling carbon within the biosphere. In this process, photosynthetic organisms, such as plants, can synthesize carbohydrates, proteins, oils, and other cellular materials using sunlight, carbon dioxide, and nutrients. Perhaps one of the most efficient converters of carbon dioxide ("CO2") to biomass is microalgae, using solar thermal 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] When using algal biotechnology, carbon dioxide capture can be advantageous due to the production of useful, high-value products, whose productivity can be improved from the use of carbon dioxide that would otherwise be released into the atmosphere as waste gases contributing to global warming. The production of algal biomass as a way to reduce carbon dioxide levels in combustion gases can be an attractive concept. Algal biomass can also be converted into high-quality liquid fuels, similar to crude oil through thermochemical conversion by known techniques such as high-temperature liquefaction (doing this economically may require the supply of waste heat and low-cost electricity), or diesel fuel (e.g., biodiesel) through transesterification of lipids in algal biomass, or even renewable diesel and jet fuel through modified petroleum refining. Algal biomass can also be used for gasification to produce highly combustible organic fuel gases suitable for use in gas-fired power plants. Algae can produce ethanol. The protein and omega-3 fatty acids in algal biomass can be a good source of food, fish feed, and even animal feed.

[0006] Algae cultures can also be used for biological nitric oxide ("NOx") removal from combustion gases. Some algae species can remove NOx over a wide range of NOx concentrations and combustion gas flow rates. Nitrous oxide (NO), the major NOx component, can be dissolved in the aqueous phase, where it can then be oxidized to nitrogen dioxide ("NO") and further taken up by the algae cells. For example, NOx removal using the algae Dunaliella can occur under both light and dark conditions (e.g., under light conditions), with an efficiency of NOx removal of approximately greater than 96%.

[0007] Over the course of 18 years, the U.S. Department of Energy (DOE) has funded an extensive series of studies to develop renewable transportation fuels from algae. In Japan, government agencies such as the Ministry of International Trade and Industry, along with private companies, have invested over $250 million in algae biotechnology. Each program has taken a different approach, but to date, large-scale commercial success has been minimal due to various issues addressed herein.

[0008] An additional beneficial use of algae would be to produce high-protein fish feed, which would restore fatty acids to them. The need for fish farms may be rapidly increasing, and the availability of fish used to feed other fish, such as salmon, may be decreasing. Therefore, many fish farms use soy and other vegetable proteins for feeding, but these substitutes do not contain the omega-3 fatty acids that make these farmed fish a valuable food. Algae have these fatty acids and therefore could be a valuable fish feed.

[0009] Additionally, algae can grow in brackish and even salt water that may be unsuitable for agriculture, potentially allowing for all the benefits of algae production without incurring serious water use problems.

[0010] A major obstacle to viable algal carbon capture, and perhaps even pollution reduction, has been the lack of an efficient yet cost-effective growth system. DOE research has shown that approximately 4 km 2 The focus of current research is on growing algae in large, open reservoirs spanning 100,000 m2. As recently as 2016, the National Algal Biofuels Technology Review Final Report (a large-scale, three-year U.S. government-funded program) concluded that "algae cultivation in algal flume and open reservoirs is envisioned as the most economical route for algal biomass and biofuel production. If the anticipated scale of biofuels is to be generated in the coming decades, algae will need to be cultivated on thousands of acres of land for the desired biomass yield." This conclusion comes from examining many closed photobioreactor designs. Essentially, flume reservoirs may require low capital input; however, algae grown in an open, uncontrolled environment can result in low algal productivity, primarily due to self-shading, which can occur as algae near the surface receive sunlight, grow, and darken, casting shadows on algae further below the surface in the reservoir. This condition is a result of the fact that within a few diameters of the paddlewheel propulsion system, the turbulence it generates decays, and there is little mixing over much of the length of the channel reservoir to bring algae from deeper parts of the reservoir to the surface and move surface algae to deeper regions in the reservoir. In addition, slower-growing algae species can contaminate the reservoir, likely due to contamination by environmental predators. Sudden reservoir deaths have occasionally been experienced. Open reservoir technology is likely to make growing and harvesting algae prohibitively expensive, as moving large volumes of dilute algal water can require very large agitators, pumps, collectors, and low concentrations of algae that require energy-intensive drying.

[0011] To reduce the above impacts, extensive research has been conducted to examine and understand the nature of biotic factors such as bacteria, viruses, invasive algal species, fungi, and herbivores in algal reservoirs that can affect algal biomass yield, and some progress has been made.

[0012] Another difficulty in using reservoirs to address point source emissions of carbon dioxide can result from the reservoir's shallow depth, which causes the carbon dioxide to rise to the surface and be released back into the atmosphere before the algae can fully utilize it.

[0013] New approaches must overcome limitations currently faced by the industry, including low overall area yields or yields per unit area, far below theoretical maximums, associated with scaling up microalgae cultures to commercial sizes. Previous attempts have been made to scale enclosed photobioreactors to industrial and commercial scales. As with open-channel reservoirs, a key problem to overcome may be the generation of mixing motion that allows all algae to receive incident light on the walls, which is necessary for uniform algae growth in these large-scale systems as the algae become more dense. The lack of extensive mixing of dense algae in large systems prevents light from reaching algae in the middle of the system (often in pipes). Summary of the Invention [Means for solving the problem]

[0014] The present application includes various aspects that can be selected in different combinations based on the particular application or need to be addressed. In various embodiments, the present application can include a vertical photobioreactor for algae growth or a combination of vertical and horizontal units.

[0015] It is an object of the present application to provide efficient utilization of carbon dioxide contained in flue gas by optimally growing algae in a bioreactor system.

[0016] It is another object of this application to utilize counter-flow dynamics between the algae fluid and carbon dioxide to engineer sufficient residence time of the gas so that the algae can maximize its utilization within the photobioreactor system. The minimum energy input required to do this may be to utilize the buoyancy of the carbon dioxide to drive the gas upward and the downward flow of the algae fluid in the downcomer in a vertical photobioreactor.

[0017] It is yet another object of the present application to provide for algae harvesting at or near the bottom of the vertical section of the bioreactor system.

[0018] It is an object of the present application to provide a modular bioreactor system that can be scalable.

[0019] It is another object of the present application to provide a bioreactor system that can be utilized on land, underwater, in reservoirs, at sea, and the like.

[0020] It is yet another object of the present application to provide algae as a useful industrial tool to reduce carbon footprint and become a profit center.

[0021] Naturally, further objects, aims and embodiments of the present application will be disclosed elsewhere in the specification, in the claims and throughout the drawings. [Brief explanation of the drawings]

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

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

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

[0025] [Figure 4] FIG. 4 shows a non-limiting example of flue gas algae-carbon dioxide separation and redistribution to downcomers for a sparging process according to some embodiments.

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

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

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

[0029] [Figure 8] FIG. 8 shows a non-limiting example graph of algae growth comparison between a GEMS photobioreactor according to some embodiments and the same round tube photobioreactor.

[0030] [Figure 9] FIG. 9 illustrates a non-limiting example of the graph of FIG. 8 with linear growth shown according to some embodiments.

[0031] [Figure 10] FIG. 10 shows a non-limiting example of thermophilic algae growth in a 6.6 inch GEMS photobioreactor versus growth in a 5.1 inch diameter round bubble column according to some embodiments.

[0032] [Figure 11]FIG. 11 shows a non-limiting example of the graph of FIG. 8 illustrating the effect of vortex modification on algae growth according to some embodiments.

[0033] [Figure 12] FIG. 12 shows a non-limiting example of a building-mounted photobioreactor system according to some embodiments.

[0034] [Figure 13] FIG. 13 shows a non-limiting example of an arrangement of multiple photobioreactor modules according to some embodiments.

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

[0036] [Figure 15] FIG. 15 shows a non-limiting example of a combination horizontal and vertical GEMS piping system according to some embodiments.

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

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

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

[0040] [Figure 19] FIG. 19 shows non-limiting examples of photographs of an algae dewatering device in response to high flow line curvature and density difference between algae and water according to some embodiments.

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

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

[0043] [Figure 22A] FIG. 22a shows a non-limiting example of an electrostatic wave node for collecting algae according to some embodiments.

[0044] [Figure 22B] FIG. 22b shows a non-limiting example of an electrostatic wave node and sinking algae according to some embodiments.

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

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

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

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

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

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

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

[0052] [Figure 30] FIG. 30 shows a non-limiting example photograph of a wire mesh reinforced vertical GEMS system according to some embodiments.

[0053] [Figure 31] FIG. 31 shows a non-limiting example of a photograph of a light used with a reinforced vertical GEMS system according to some embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0054] It should be understood that the embodiments include various aspects that can be combined in different ways. The following description is provided to list elements and describe some of the embodiments of the present application. Although these elements are listed in an initial embodiment, it should be understood that they can be combined in any manner and in any number to create additional embodiments. The variously described examples and preferred embodiments should not be construed to limit the embodiments of the present application to only the explicitly described systems, techniques, and applications. The specific embodiment or embodiments shown are examples only. The specification should be understood as supporting broad claims and claims from which each embodiment, and even other embodiments, may be excluded, and so it is intended. Importantly, the disclosure of merely an exemplary embodiment is not meant to limit the scope of other, more comprehensive claims that may be made, when such may be merely one of several ways or embodiments that may be employed in the broader claims, etc. Moreover, this description should also be understood to support and encompass descriptions and claims of all various embodiments, systems, techniques, methods, devices, and applications, including any number of the disclosed elements, including each element alone, and including all of the various permutations and combinations of all elements in this or any subsequent application.

[0055] Embodiments of the present application include technologies that may provide: scalability; drive using compressed air or flue gas, or nitrogen separated from flue gas; growth-enhanced mixed-spectrum mixing techniques; molecular filtration for carbon dioxide separation; carbon dioxide rerouting; separate introduction of carbon dioxide to possibly produce buoyancy-induced carbon dioxide counterflow; algae fluid velocities that may allow for controlled gas residence times; natural algae coagulation; electrostatic standing wave coagulation enhancement; screen dewatering using Coanda screens or the like; centrifugal force via high flow curve algae / water separation and recovery, phototrophic, mixotrophic, or heterotrophic operation; automated filling, growth, and recovery; modularity; low capital cost; low operating cost; low land area, any combination or permutation thereof, etc.

[0056] Embodiments of the present application may address the following problems: carbon utilization for carbon sequestration; carbon dioxide negative organic fertilizer production for improved agriculture versus chemical fertilizers; oil for renewable diesel and jet fuel; higher value product production; renewable sugar production; any combination or permutation thereof, etc.

[0057] Growth-enhancing mixed-spectrum ("GEMS") mixing technology can be used with photobioreactors such as those discussed in International Publication No. WO 2020 / 237103 A1 to SolarClean Fuels, LLC (herein incorporated by reference). This can include tubing that allows light to pass through to the algae contained therein. The tubing can have spiral impressions, which can affect fluid and algae flow through the bioreactor. Such spiral impressions can be used to allow proper residence time for the algae in light and dark regions as they move through the photobioreactor.

[0058] Unlike that discussed in WO2020 / 237103A1, embodiments of the present application provide a vertical growth-enhanced mixed-spectrum photobioreactor system, which may include, but is not limited to, incorporating GEMS mixing motion, using carbon dioxide concentrate from flue gas (or other source), routing carbon dioxide upward against the downward flowing algae, providing counter-flow controlled residence times for maximum algae utilization of carbon dioxide, using low power and even providing air or flue gas driven reactors with low shear stress, incorporating nano or micro bubbles for sparging at the bottom of the downcomer, incorporating high flow line curvature for dewatering, any permutation or combination thereof, etc.

[0059] An embodiment may include a photobioreactor system, the photobioreactor system including at least one downcomer tower having a spiral pattern configured to provide enhanced growth and spectrum mixing in the downcomer tower; a riser tower connected to the at least one downcomer tower; an algae-fluid input configured to input a fluid having algae into the at least one downcomer tower near a top of the downcomer tower and configured to generate an algae-downward fluid flow in the downcomer tower; and an algae-fluid input configured to input a gas into the riser tower near a bottom of the riser tower and configured to generate an algae-downward fluid flow in the riser tower. a gas input configured to generate an upward flow and drive system flow; a carbon dioxide gas input configured to input carbon dioxide into the at least one downcomer tower near a bottom of the downcomer tower and configured to generate an upward flow of carbon dioxide gas in the downcomer tower; a counter-current generated with the downward fluid flow of the algae and the upward flow of carbon dioxide gas in the downcomer tower configured to enable optimal reaction between the algae and the carbon dioxide, and possibly even a collection tank configured to collect mature algae from the downcomer tower.

[0060] Other embodiments may include a method of using a photobioreactor, the method comprising the steps of: providing at least one downcomer tower having a vortex pattern; generating enhanced growth and spectrum mixing in the downcomer tower using the vortex pattern; connecting a riser tower to the at least one downcomer tower; inputting a fluid having algae into the at least one downcomer tower near a top of the downcomer tower using a fluid input; generating an algae-downward fluid flow in the downcomer tower; inputting a gas into the riser tower near a bottom of the riser tower using a gas input; driving system flow using a carbon dioxide input into the at least one downcomer tower near the bottom of the downcomer tower; generating a gas upward flow in the downcomer tower; generating a carbon dioxide gas upward flow in the downcomer tower; generating a counter-current flow in the downcomer tower with the algae downward fluid flow and the carbon dioxide gas upward flow; optimally reacting the algae and the carbon dioxide in the counter-current flow, and possibly even collecting mature algae from the downcomer towers in a collection tank.

[0061] As can be seen from Figures 1 and 2, a vertical enhanced growth-enhanced mixed-spectrum photobioreactor system ("VGEMS PBR") (1) may include three towers: a middle riser tower (21), which may be called a central tower, vertical riser, or riser, and two outer towers (22), which may be called downcomers or vertical downcomers. Note that any configuration (middle, outer, inner) and any number of towers may be used. The towers may be columns, vertical tubing, structures, risers, etc. The towers (or some of the towers and / or tubing in the system, or perhaps all of the towers and / or tubing) may have a swirl pattern (211) that causes GEMS in the fluid flow. The system may be powered by gravity, buoyancy assistance, carbon dioxide fermentation, gas lift, air, flue gas, nitrogen, the use of pumps, gas compressors, etc. A gas or gases (23), perhaps pure carbon dioxide, gas with at least some carbon dioxide, etc., can be input (18) into the intermediate riser tower, perhaps at or near the bottom (24) of the tower, so that the gas can flow upward (20). The gas (23) can be air, flue gas, nitrogen gas separated from flue gas, gas from a chimney, carbon dioxide from the atmosphere, carbon dioxide gas, etc. The gas can be utilized as a driving force or propellant for the bioreactor. Depending on the type of gas, the tower and system can be modified for efficiency. For example, if the only available carbon dioxide is from the atmosphere, the tower may need to be taller and the sparged bubbles smaller, since there may not be much carbon dioxide to start with and all may be needed.

[0062] After flowing through the central riser, the gas (23) may be filtered using a filter (16), whereby the filtered gas (e.g., oxygen and nitrogen) may be released to the atmosphere, possibly using a gas vent (17), and the carbon dioxide may be recycled (15) to the outer tower (22), possibly using a gas circulation component (231), which may be pipes, tubing, etc. In some embodiments, the flue gas may be unfiltered. In embodiments, the carbon dioxide gas may 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 carbon dioxide gas may be used as a counterflow (230) to the algae moving downward in the downward fluid flow (25) in the downcomer. The counterflow may allow for optimal reaction between the algae and the carbon dioxide, which may be an optimal amount of reaction time in mixing the algae and the carbon dioxide. Water containing algae and fresh nutrients can be input (10) at or near the top of the tower (212). As the carbon dioxide interacts with the algae, it is reduced as it is 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, there could be no carbon dioxide in the fluid at location (2).

[0063] FIG. 2 provides another example of a VGEMS PBR, including, but not limited to, the following: fluid, algae, and even nutrient inputs (29); clear polyethylene tubing (33) with a tested diameter of 6.6 inches (although any size can be used); a GEMS vortex (34) that can circulate algae in and out of the light, accelerating algae growth; carbon dioxide input (35); a low-pressure compressed air source (37) directed above the central riser to drive system circulation as system flow (250); an upward gas flow (38) that can provide buoyancy-driven recirculation of algae and nutrients to the outer tower (30); an interaction area between the algae and gas (39); a sparger (5) that can generate small gas bubbles, such as nanobubble-sized or microbubble-sized; a gas release (32) of nitrogen, oxygen, etc.; a defoamer pipe (31) that can vent the released gas and foam (if it forms), etc. The tower height (28) can vary. A 17-foot tall tower was tested, but the optimum height will depend on the algae, overall flow rate, incoming gas, and sparged bubble size. Figures 3, 18, 30, and 31 show non-limiting examples of VGEMS PBR systems that may be constructed.

[0064] Figure 4 shows a non-limiting example of recirculation in a VGEMS PBR system. The upper portion of the middle tower (21) and two outer towers (22) are shown. Unrecovered algae and fluid can be recirculated (54) from the middle tower into the outer tower. CO2 absorption liquid and / or antifoam liquid (52) can be stored in a trap (53). Gas (51), such as air, flue gas, nitrogen, oxygen, or trace gases, can be contained in tubing in the upper part of the VGEMS PBR system. Here, foam (50) during processing can be allowed to break down and dissolve back into the fluid. A valve (53) can be provided to purge the liquid stored in the trap for reprocessing (if an amine) or recirculation. The carbon dioxide may be filtered using a filter (49), nitrogen, oxygen, trace gases, any combination thereof, etc. (46) may be released, and the carbon dioxide (55) may be recycled (48), perhaps using a circulation component to a sparger, or compressor, or tank, etc.

[0065] As mentioned herein, embodiments may provide that the bioreactor may be powered using flue gas, perhaps from a flue stack. Some flue gas may be about 85% to about 90% nitrogen and about 10% to 12% carbon dioxide. Most of the oxygen in the flue gas may be combusted in the flue stack. The flue gas may be input to the photobioreactor in a central tower. In some embodiments, the flue gas or air may be used directly; in others, the flue gas or air may be filtered to separate the nitrogen from the carbon dioxide in the flue gas, perhaps because nitrogen may not be needed and may unnecessarily occupy volume in the system. Some types of algae, such as extremophilic algae, may be able to utilize unfiltered flue gas or air. Figure 14 shows one type of filter, a graphene filter (91), which has carbon dioxide-selective polymer chains attached to the graphene, which can extract carbon dioxide from the flue gas. Flue gas containing a mixture of gases (92), such as nitrogen, carbon dioxide, heavy metals, and oxygen, can pass through a filter to separate the carbon dioxide (93). When the flue gas passes through the filter, nitrogen cannot pass through, but carbon dioxide can. The filter can be located at or near the top of the VGEMS PBR or in the central riser tower. Alternatively, a filter, such as a MOF filter, can be located centrally, and appropriate piping and pumping systems must be added to the VGEMS PBR array. The filtered carbon dioxide can be piped to the outer downcomer tower, perhaps to the bottom of the tower, so it can permeate upward into the outer tower. The filtered nitrogen and any remaining oxygen can be released to the atmosphere or collected, compressed, and used as drive gas in some VGEMS PBRs.

[0066] Any type of filter, membrane, molecular filter, metal oxide framework filter, etc., can be used, and they can be located anywhere in the system, and the use of one or more filters can be used. In some embodiments, a single carbon dioxide filter can be used, perhaps with two or more centrally located photobioreactors. In embodiments, high-performance membranes can be used. Such types of membranes can be environmentally friendly, generate no waste, enhance chemical processes, and can be used in a decentralized manner. Membranes can be based on single-layer graphene with selective layers thinner than 20 nm and have highly tunable chemical properties. In the past, membranes could exceed 1,000 gas permeance units (GPUs) and have carbon dioxide / nitrogen separation factors greater than 20, which can be a measure of their carbon capture specificity. Newer membranes can have a carbon dioxide permeance six times higher, approximately 6,180 GPUs, with a separation factor of 22.5. An increase in GPU, possibly up to 11,790, can also be achieved when optimizing graphene porosity, pore size, and functional groups (e.g., chemical groups that actually react with carbon dioxide).

[0067] As mentioned, carbon dioxide or a gas containing carbon dioxide can be input (27) into a sparger at or near the bottom of each of the two outer towers to provide an upward flow of gas (26) countercurrent to the algae (230) (as the algae flow downward and the carbon dioxide flow upward). A sparger, which may be a fine-mesh disk, microbubble generator, nanobubble generator, or the like, possibly with sensors, can be located at the carbon dioxide input (27), where the carbon dioxide can be pushed through the disk to provide fine bubbles. Because the carbon dioxide bubbles, as a gas, can be lighter than the surrounding liquid, they can rise up the tower, thus creating an upward flow velocity. The algae in the liquid can be located within the tower and have a downward flow (25) in each of the outer towers. Such downward flow can act against the upward flow of the carbon dioxide. The downward flow can be adjusted, perhaps to keep the carbon dioxide bubbles near the middle of the tower, since the bubbles cannot rise faster than the downward flow against them. This may be a manifestation of countercurrent flow. In the downcomer tower, the carbon dioxide upward velocity is moderated by the downward flow, possibly using a downward fluid flow rate regulator (232) (which may be adjusted by the force of the downward flow), so the algae have time to react with and consume the carbon dioxide gas bubbles. In some cases, the carbon dioxide may never reach the top of the tower. This may be an optimal condition. In other cases, any remaining carbon dioxide may be reused, such as by being recycled to an outer GEMS tower where the CO2 may be utilized. The algae can use substantially all of the carbon dioxide and be allowed sufficient residence time in the tower to provide an efficient carbon dioxide utilization system. This is particularly true if the reserved bubble size is kept small, even if it may be required to be in nanobubble size form.In past horizontal systems, carbon dioxide bubbles could rise to the top of the pipe, forming a carbon dioxide cloud, and be pushed along with the liquid, leaving excess carbon dioxide to vent to the atmosphere, which may be undesirable; however, the use of counter-flow dynamics with carbon dioxide in a vertical photobioreactor can provide for the majority of the growing algae to be exposed to the carbon dioxide counter-flow for most of its lifespan for maximum carbon dioxide utilization by the algae.

[0068] As algae flow through the GEMS photobioreactor, they may experience periods of light and dark as they move between the middle and outside of the tower GEMS pipes. The system may include a cross-flow timescale during which the algae are moved between light and dark regions. This can be adjusted depending on the type of algae used, the average flow rate, and the depth and pitch of the GEMS whorls. Controlling the light / dark cycle through the depth and pitch of the whorls and the average flow rate in the presence of optimal carbon dioxide and nutrients can lead to the fastest algae growth and the fastest carbon dioxide utilization.

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

[0070] Bubble sizes can range from millimeters, microns, and nanometers. Regarding carbon dioxide utilization by algae in the downcomer, it may be desirable to use the smallest bubble size possible to achieve complete utilization of the carbon dioxide introduced into the downcomer over the contact time with the algae. Due to countercurrent flow interactions between the algae and carbon dioxide in the downcomer, optimal contact times can be utilized. The bubble size can provide bubble rise time, and the countercurrent flow velocity can be adjusted to allow carbon dioxide interaction with the algae. There may be an optimal velocity range for crossflow motion in the pipe of a VGEMS PBR; therefore, the bubble rise velocity may need to be slightly greater than the downward flow, and the bubble size may need to be optimized so that all or substantially all of the carbon dioxide is utilized before reaching the top of the downcomer. The optimal countercurrent flow velocity may be a function of the bubble size and even the characteristics of the algae.

[0071] In embodiments, nanobubbles may be used in the downcomer, and the nanobubbles may be introduced in a volume that may allow for GEMS movement to distribute the bubbles and the carbon dioxide they carry to all the algae in the downcomer that may need carbon at a given time. In embodiments, microbubbles or nanobubbles may not be needed in the riser, although under certain gas mixing circumstances they may be used.

[0072] The VGEMS PBR counterflow flank may offer further engineering design optimization potential. For example, if smaller bubbles are used, the required downcomer height may be shorter and still allow for complete carbon dioxide utilization by the algae. This may lead to lower greenhouse costs, the use of lower pressures at the bottom of the VGEMS tower, and the use of less robust (e.g., lower cost) materials. Part of the balance may involve the higher cost of the smaller nanobubble size production device and the additional money required for temperature control.

[0073] Embodiments may provide other methods for increasing not only algae growth rates but also optimal carbon dioxide uptake, possibly including microbubble sparging devices in the downcomer pipe as discussed herein, pulsed bubble generation, and counter-current carbon dioxide and algae flow, increased residence time, any combination thereof, etc.

[0074] Figures 8-11 provide graphed results from an experiment comparing algal growth between a vertical GEMS photobioreactor and a round-tube photobioreactor. The PBR was a three-column vertical round-pipe PBR with pipes of the same diameter and height but without the GEMS modifications. The PBR was identical to the VGEMS system: it had the same size, flow rate, counterflow velocity, and sparging, the same upper and lower manifolds, and the PBR used the same algae, nutrients, drive air, and CO2 inputs. However, the PBR was not modified by GEMS. Figure 8 shows algal growth in a vertical GEMS photobioreactor (75) versus a round-tube photobioreactor (76). As shown in Figure 9, the VGEMS PBR results provided an initial linear growth rate (77). A new, better linear growth rate (78) developed later in the experiment. Here, cyanobacteria (PCC11901) grown in a 4.5-inch diameter vertical GEMS PBR pipe exhibit a faster initial linear growth rate (77) and a faster growth rate than horizontal round pipe growth (78). This is attributed to the optimization of the light-dark cycle in the vertical GEMS PBR pipe. In the round pipe, the algal growth rate slows to zero (79) as the algae become denser.

[0075] Figure 10 provides another example using the thermophilic red alga C. merolae. Again, a second linear growth rate (80) was produced in the vertical GEMS PBR. This growth rate was slower than the initial growth rate. However, growth in the vertical GEMS PBR persisted for nearly twice the growth period compared to algal growth in the round pipe (81). The vertical GEMS PBR was capable of producing twice the density of algae to be harvested after approximately 60 days (note that the experiment here was stopped after 48 days and then restarted). This experiment was performed at a high temperature (°C). Merolae was grown in a 6.625-inch diameter VGEMS PBR pipe and compared to data grown in a 5.1-inch diameter round pipe bubble column.

[0076] In embodiments, the light / dark cycle can be adjusted for each specific type of algae to produce a higher growth rate than that obtained with the initial linear growth rate. This can be accomplished by adjusting the depth of the spiral, perhaps using the spiral adjuster (233), and perhaps also by adjusting the flow rate for the specific algae. Thus, the cross flow velocity (and therefore the time it takes for the algae to travel down the pipe and encounter light at the wall) can be adjusted. Figure 11 compares different growth rates with hypothetical faster ones. Algae grown in a round pipe reduces its growth rate to zero (82) after a period of time. Algae grown in a pipe with a spiral radius of about 0.3 can have a growth rate (83) as shown. Algae grown in a pipe with a spiral radius of about 0.44 (depth of the spiral compared to the radius of the pipe) can have a growth rate (84) as shown. The hypothetical growth rate (85) assumes algae grown in pipes with a whorl radius of approximately 0.55. It is believed that algae growth rates increase as the whorl depth increases. Therefore, optimizing the depth of the whorl can be advantageous in optimizing these systems.

[0077] A vertical GEMS PBR system can offer special benefits that may enable better algae recovery. As the algae flow travels down the downcomer, some coagulation may occur, and if the algae mass is heavier than the water, the algae (135) will settle into a collection section at the bottom, as shown in FIG. 20. In addition, electrostatic standing wave coagulation may be induced, as shown in FIGS. 22a and 22b. Thus, initial coagulation may be strengthened at the nodes of the electrostatic wave, as shown in FIGS. 22a and 22b. The standing wave may be generated by electrostatic forces. The algae may aggregate and coagulate at the nodes of the standing wave.

[0078] In collecting grown algae that descends downward from the downcomer, the Coanda effect, gravity, and centrifugal force can be utilized for algae and water separation. Figure 5 provides a non-limiting example of algae collection near the bottom (200) of the downcomer tower. The algae and fluid can move in a downward flow (58) in the downcomer. The algae can be coagulated using an algae coagulator located near the bottom of the downcomer tower, possibly utilizing positively (57) and negatively (56) charged plates connected to the system. A Coanda screen (61) can be utilized in the downcomer to cause larger mature algae and algae clumps (59) to be directed and fall around the sides (60) of the Coanda screen and into a collection tank (64). The smaller algae and fluid may be routed to pass through the screen (62) and flow (163) through high flow bends (161) in the piping, allowing the fluid and smaller algae to be recirculated (63) through the system. Valves, which may be automated, may open and close to collect the algae in a collection tank. For example, valve (65) may close and valve (66) may open to withdraw the collected algae (64) from collection tank (64).

[0079] More specifically, algae can be collected using the curved streamlines of the VGEMS PBR system. The inertia of heavier, larger, and more mature algae particles can cause them to move in their current direction (e.g., in a straight line or in a line straighter than the streamlines created in the overall VGEMS PBR geometry). Lighter algae, fluid, and other less dense particles, such as nutrients, can flow along the streamline curves, which can be recirculated in the system. Gravity and the high streamline curvature (161) in the pipe can aid in continuous algae collection. Algae can be denser than water, so that when the vapor flow of the algae and water mixture reaches the high streamline curvature in the pipe, the algae and heavier algae may not follow the flow direction of the streamline curvature (74) and may fall into the bottom of the tower, while the fluid follows the curvature, allowing for separation of the algae particles as shown in FIG. 7. Figure 19 provides a photograph showing a non-limiting example of high bends in the piping of a vertical GEMS PBR system, which can provide a high-bend flow (74) and enable the recovery of grown algae. Here, a non-limiting example of PVC pipe is used to provide a curved streamline effect. The geometry is such that the algae travels below the level required to make a turn to proceed into the riser, then is pushed upward to continue its circulation path to the riser. The manifold is constructed from prefabricated 6-inch diameter PVC sections and has a 135-degree bend at the elbow joint. Liquid flow can descend from the two outer downcomer pipes, be accelerated by the area contraction, and then proceed up the center riser to complete the circuit. The flowing algae will need to travel around the 135-degree bend in the streamline bend. The system can be designed with any size piping and any shape of bend to optimize the recovery of grown algae. The inside radius of the turn can be adjusted to reduce shear effects. Algae that cannot make the turn can fall into the collection area (see arrow).

[0080] It may be desirable to optimize flow forces so that mature, heavier algae do not make turns and therefore move downward into the collection area. Parameters may involve a combination of the downcomer's average flow velocity and the radial velocity of the average flow streamline at the return bend, which is generated by the curvature of the streamline at the bend. The system can be custom-fabricated, possibly using custom molds, and thus the curvature radius of the bend can be customized. There may be a wide range of flow velocities to evaluate in creating customized systems for use with different types of algae (including, but not limited to, microbubble size, counterflow dynamics, number of bends, freedom of area ratio at the bend, etc.). Instantaneous velocity may play a role in the final trajectory of any algal cell; therefore, it may take several circuits around the VGEMS PBR before the algal cell (even a mature cell) can fall into the collection area and be collected. The final custom configuration may be determined by trial and error, but the same concepts may be embodied in all subsequent configurations.

[0081] Depending on the cell wall toughness, density differences, and possibly size of the algae cells, separation of fluid and water from the algae cells can be achieved. An algae filter and dewatering device can be configured to filter mature algae and remove water from the mature algae, possibly using the Coanda effect. Figure 6 shows the arrangement of a Coanda screen (61). The Coanda screen or other type of filter can be bell-shaped, directing fluid flow (67) from an upstream pool (68). It can include an acceleration plate (69) and possibly a toothed wedge wire screen (70). The Coanda effect (71) can keep the flow attached to the upper surface of each wire screen. The angled wires can shear the flow through the screen. Diverted flow (72) and bypass flow (73) are shown. As the fluid flow and algae pass through the screen, the fluid may flow around the corner and back into the bioreactor, while the coagulated algae may be collected near the bottom for collection. The screen may allow small algae along with the water to pass through the screen (possibly for further growth), but the screen may deflect larger clumps of algae around the sides of the screen for collection in a collection tank. The smaller algae may migrate within the tower and be recirculated. Without a screen, all of the algae in the tower may continue to recirculate and may be difficult to concentrate for collection. With a filter or screen, larger clumps of algae may be separated. Collection of the algae may be easier with a screen, perhaps because the algae may not have much water with it. In an embodiment, Asparagopsis algae (136), shown in FIG. 21, may be separated using a Coanda screen. Of course, a combination of physical effects can be utilized to optimize dewatering and recovery, for example, a sequential system of Coanda screens and high curvature centrifugal dewatering may complement each other.

[0082] The system may be modular and scalable. Modularity may allow for organic growth of the bioreactor system. With a large number of modules, maintenance of any module in the system may be virtually uninterrupted to overall operation. Scalability may allow the bioreactor system to meet individual needs, which may be large as well as small.

[0083] Figure 3 shows a non-limiting example (1) of a vertical GEMS photobioreactor system with multiple VGEMS PBRs connected together. These figures show a schematic of piping that can be used for automatic recharging and draining of the connected VGEMS photobioreactors (42). A material input (10) can flow into the system (43), possibly via a single pipe or multiple pipes. This input can include fluid, algae, algae feedstock, nutrients, any combination thereof, etc. Such inputs can then flow into each VGEMS PBR unit (44); here, five units are shown in Figure 3; however, any number of reactors can be combined. Each bioreactor can be separately controlled using a separate operational controller, which can be automatic, can respond to sensor inputs from each separate system, and can control valve inputs (40) and valve outputs (41) using multiple valves in each system. Once ready, mature algae and fluid can be output from each bioreactor, possibly via output (11). (The aforementioned Coanda and high-curvature dewatering equipment geometries are not shown in the schematic diagram.) New inputs, such as fluid, algae feedstock, nutrients, etc., can then be refilled and entered into each bioreactor, algae can be allowed to thrive, and when ready, algae and fluid can be output again. Some algae may perhaps remain in the system for new algae production. This cycle can be refilled and emptied as many times as necessary. Operation can be fully computer controlled, as can be governed by sensors. Sensors may indicate that one or more modules are ready to be harvested at any given time, although the diagram may indicate that the five modules shown are being harvested simultaneously. In embodiments, portions of the system, or even the entire system, may be automated.

[0084] The system can be scaled up by making the pipes larger and replicating them into a larger system. In some embodiments, the modular system can be organically expanded as needed. For example, a user can start with five VGEMS PBRs, then add about five more as the company grows, etc. Each VGEMS PBR can be a different size, using larger pipes, longer pipes, smaller pipes, shorter pipes, etc. As the VGEMS PBR system gets larger, the overall capital cost can be lower, especially due to the use of flexible plastics and also due to fewer valves required for a given volume, fewer leaks, etc.

[0085] A VGEMS PBR system can be added to an existing building (87), as shown in the non-limiting example of Figure 12. A new system (88) can be attached to the side of the building, perhaps in a single layer of connected VGEMS PBRs (86). Each bioreactor can be connected to form a configuration. For example, a stack can have six 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 arrangement, etc. The side of the building with the VGEMS PBR can be facing south to take advantage of sunlight. The modularity of the system can allow versatility in use to adapt to the user's needs. Figure 13 shows a non-limiting example of an arrangement of 380 VGEMS PBR modules on four downcomers and one riser. Depending on the size of the modules and system, this could be installed in a half-acre building or the like. Each VGEMS PBR (86) can be located within the building (89). They may be organized in rows and columns, and the rows may be spaced apart by a distance (90), such as about 6 feet apart, for fire and maintenance purposes.

[0086] As mentioned herein, embodiments of the present application may include systems with valves (such as solenoid valves) that can be automatically operated, perhaps using a computer program, to open and close the valves. Valves can be included in each VGEMS PBR module, in each tower of each module, and connected in an array of modules. Valves can serve to fill and empty reactors, whether for one VGEMS PBR or multiple reactors ranging from about 5 to about 500 or more. A valve, possibly computer-controlled, can be located at the top of a vertical photobioreactor system, with another valve perhaps located at the bottom. A pressurized feeder line input can feed nutrients and perhaps algae feedstock into the system as needed. An output line can be a suction line to withdraw algae when they are mature and ready for further harvesting. Bioreactors can be emptied individually, or, if attached to each other, can be emptied together, or the system can select which bioreactors to empty at different times. The input, which may be a pipe, is under pressure and may be filled with nutrients, but in some cases, nutrients cannot be input into the bioreactor until a valve is opened. To fill an empty reactor, the top valve may be opened and the bottom valve may be closed. There may be some gas that needs to be released. Once the VGEMS PBR is full, the algae may cycle and grow, and after perhaps a certain amount of time (e.g., about 5 days, about 10 days, it may be any time based on the type of algae), it can be emptied. Once emptied, the VGEMS PBR may be cleaned and refilled to begin a new cycle. Sensors in the system may provide data so that the system can automatically determine when the bioreactor needs to be filled, emptied, etc. Additionally, embodiments may provide an automated system, where the harvesting and intermittent refilling of the bioreactor may be continuous.

[0087] Embodiments may provide a VGEMS PBR system that can be located on land, underwater, on water, in bays, on power plant cooling ponds, etc. Underwater, such as in the ocean, the system can be tethered to a structure such as a wind turbine, the seabed, etc. Underwater, the temperature of the ocean can be used to moderate the temperature of the VGEMS PBR. In some embodiments, approximately one-third (or more or less) of the bioreactor section can float above the ocean surface and be exposed to sunlight (which can be adjusted using floats). In some situations, mixotrophic algae can be used, which can grow in both dark and light conditions and can be mixed between light and dark areas of the reactor. The VGEMS PBR system can be located adjacent to a coal-fired power plant, a wastewater treatment plant, etc., and can utilize carbon dioxide waste and / or wastewater therefrom, as discussed in more detail herein. In embodiments, the bioreactor may be floating underwater or in a cooling pond, perhaps to avoid occupying land space. Such a system may be a closed loop and may avoid additional building costs.

[0088] Embodiments may provide increased algae production per acre, likely due to the vertical nature of some systems. Traditional algae growth systems occurring in reservoirs may simply be horizontal systems. Some algae can survive on very little carbon dioxide and can survive for long periods of time where carbon dioxide from the air may be sufficient to support the system. Such systems may be effective in direct air capture systems or may be used in combination with other direct air capture systems that can concentrate carbon dioxide.

[0089] In embodiments, a photobioreactor system may include a combination of vertical and horizontal piping systems, such as that shown in the top view of the system in Figure 15. Horizontal systems may be understood from WO 2020 / 237103 A1. Combinations of vertical risers and downcomers or horizontal GEMS pipes and vertical GEMS pipes may be used in various systems. Figure 15 shows four VGEMS PBR modules (95) connected to horizontal piping (94). Including horizontal PBR in a system can result in lower costs, as long as there is enough space to include the horizontal PBR section. The horizontal section of the system may require one of many possible methods to allow gases and fluids to travel along the pipes (96). This may be accomplished by attaching short sections of the volute with spacers to allow gas passage, attaching short sections using various connectors that allow gas passage, pushing the volute into place, etc.

[0090] In embodiments, direct air capture may utilize filters to separate carbon dioxide from atmospheric air and concentrate it, which can then be used to grow algae faster. In this type of application, perhaps four to six downcomers per riser may be used, although any configuration may be used. Maximizing counterflow mass may be desirable. Risers used for this purpose may not need to be GEMS risers, since compressed air would be the driving gas, although GEMS may be used.

[0091] Risers, downcomers, their piping, and tubing can be made from plastic materials. Continuous testing of the fracture strength, tensile strength, and transparency of LLDPE and catalyst mixtures of metallocene and other catalysts may be required to improve the material combinations used in the piping. Their construction may include methods for the construction of the volute; possible correlation of the volute depth with the ground slope to facilitate gas passage; and, if the application requires rigid tubing, volute grooves can be stamped during pipe extrusion using ball bearing races bolted onto the extrusion machine. For soft plastics, mesh coatings can be used, which can broaden the range of plastics that can be used. Metallocene-catalyzed linear low-density polyethylene, as a non-limiting example, offers 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 allow inexpensive plastics (for rigid pipes) to be used in many cases.

[0092] In embodiments, the system can be designed based on the algae used and also based on the industrial situation. The bioreactor system and its configuration can be constructed to accommodate the rate of waste flow that needs to be handled, as well as the speed at which the algae can be moved without damage, due to the higher velocity in the central riser tower. For example, the larger the diameter of the central tower, the slower the algae will move in the riser while still being able to have the necessary velocity in the peripheral outer towers, which may be downcomers, to optimize CO2 uptake by the algae. Thus, in embodiments, the vertical bioreactor system can have any of a variety of configurations, including, but not limited to, one, two, three, four, five, six, seven, eight, nine, ten, or more downcomer towers, possibly with a single riser tower, as can be seen from Figures 23-29. This can be determined by the type of algae used and the application being utilized. The central riser tower (137) may be of smaller or even larger diameter for any configuration of downcomer (138), depending on the available energy input and perhaps even the velocity the algae can handle.

[0093] Embodiments may include the integration of a VGEMS PBR system with other industries. Figure 16 shows an integrated ethanol-corn-fertilizer-algae system, and Figure 17 shows an integrated coal or natural gas-wastewater-algae system. In Figure 16, a corn field (102) can be used to grow food and fuel, utilizing carbon dioxide (99) and water (101). Of course, other crops could be used instead. A fertilizer plant (98) could convert methane (97) into ammonia and nitrogen (100) that could be used by the corn field; such a reaction could release carbon dioxide (112) from the plant. These carbon dioxide emissions (112) could be fed to an algae photobioreactor system (210). Corn (103) could be harvested from the field and processed in an ethanol plant (104) to provide ethanol (105), cattle feed (106), or even renewable jet fuel (107). The ethanol plant may also produce carbon dioxide emissions (110), thin stillage (109), and waste heat (108), which may be input into the algae photobioreactor system (210). Fertilizer used in corn fields may provide high ammonium effluent (111), which may be fed to and aid in the growth of algae in the photobioreactor system (210). The algae photobioreactor system (210) may include a VGEMS PBR (113), a horizontal photobioreactor (114) with or without GEMS, and any combination or permutation thereof. The photobioreactor system (210) can produce oil (115) that can be used in renewable jet sustainable aviation fuel (121), nutritional supplements (116) that can be used in omega-3 and omega-6 supplements (122), organic fertilizers (117) that can be used with organic produce (123), astaxanthin (118) that can be used with human antioxidants (124), proteins (119) that can be used for cattle, fish, etc. (125), and possibly phycocyanin (120) that can be used for humans and food (126).

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

[0095] While the present invention has been described in connection with several embodiments, it is not intended to limit the scope of this application to the particular forms described, but on the contrary, it is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of this application. Examples of alternative claims may include:

[0096] 1. A photobioreactor system, comprising: at least one downcomer tower having a spiral pattern configured to provide enhanced growth and spectral mixing in the downcomer tower; a riser tower connected to the at least one downcomer tower; an algae-fluid input configured to input an algae-bearing fluid into the at least one downcomer tower near an upper portion of the downcomer tower, the algae-fluid input configured to generate an algae-downward fluid flow in the downcomer tower; a gas input configured to input gas into the riser tower near a bottom of the riser tower, the gas input configured to generate an upward flow of gas in the riser tower and drive system flow; a carbon dioxide gas input configured to input carbon dioxide into the at least one downcomer tower near a bottom of the downcomer tower and configured to generate an upward flow of carbon dioxide gas in the downcomer tower; a countercurrent flow created with a downward fluid flow of the algae and an upward flow of the carbon dioxide gas in the downcomer tower configured to allow optimal reaction between the algae and the carbon dioxide; a collection tank configured to collect mature algae from the downcomer tower; and A system comprising:

[0097] 2. The system of claim 1 or any other claim, wherein the optimal reaction between the algae and the carbon dioxide comprises an appropriate amount of reaction time in mixing the algae and the carbon dioxide.

[0098] 3. The system of claim 1 or any other claim, wherein the at least one downcomer tower comprises at least two downcomer towers.

[0099] 4. The system of claim 3 or any other claim, wherein the at least two downcomer towers are each located outside the riser tower.

[0100] 5. The system of claim 1 or any other claim, wherein the riser tower comprises the vortex pattern configured to provide the enhanced growth and spectral mixing in the riser tower.

[0101] 6. The system of claim 1 or any other claim, further comprising a sparger near the carbon dioxide gas input and near a bottom of the downcomer tower, the sparger configured to generate gas bubbles with the carbon dioxide gas.

[0102] 7. The system of claim 4 or any other claim, wherein the gas bubbles have a gas bubble size selected from nanobubble size and microbubble size.

[0103] 8. The system of claim 1 or any other claim, wherein the fluid having the algae comprises nutrients in the fluid.

[0104] 9. The system of claim 1 or any other claim, further comprising a filter located near a top of the riser tower and configured to filter carbon dioxide from the gas.

[0105] 10. The system of claim 9 or any other claim, further comprising a gas outlet configured to release another gas filtered from the gas, the other gas being selected from nitrogen, oxygen, trace gases, and any combination thereof.

[0106] 11. The system of claim 1 or any other claim, wherein the gas is selected from carbon dioxide, air, flue gas, and chimney gas.

[0107] 12. The system of claim 9 or any other claim, further comprising a gas circulation component configured to circulate the filtered carbon dioxide to the bottom of the downcomer column.

[0108] 13. The system of claim 1 or any other claim, wherein the countercurrent flow generated with the downward fluid flow of algae and the upward flow of carbon dioxide gas in the downcomer tower is configured to consume the carbon dioxide using the reaction between the algae and the carbon dioxide.

[0109] 14. The system of claim 13 or any other claim, wherein the countercurrent flow generated with the downward fluid flow of algae and the upward flow of carbon dioxide gas in the downcomer tower is configured to consume substantially all of the carbon dioxide using the reaction between the algae and the carbon dioxide.

[0110] 15. The system of claim 1 or any other claim, wherein the tower is made from transparent tubing.

[0111] 16. The system of claim 9 or any other claim, wherein the filter is selected from a graphene filter, a membrane, a molecular filter, and a metal oxide framework filter.

[0112] 17. The system of claim 6 or any other claim, wherein the sparger comprises a fine mesh disc, a microbubble generator, or a nanobubble generator.

[0113] 18. The system of claim 1 or any other claim, further comprising a downward fluid flow rate regulator configured to regulate the rate of the downward fluid flow in the downcomer column.

[0114] 19. The system of claim 1 or any other claim, further comprising a spiral adjuster configured to adjust the depth of the spiral within the tower.

[0115] 20. The system of claim 1 or any other claim, further comprising an algae filter and dewatering device near the bottom of the downcomer tower configured to filter mature algae in the downcomer tower, remove water from the mature algae, and direct the filtered mature algae to the collection tank.

[0116] 21. The system of claim 1 or any other claim, further comprising an algae coagulator near the bottom of the downcomer tower configured to coagulate mature algae in the downcomer tower.

[0117] 22. The system of claim 21 or any other claim, wherein the algae coagulator comprises a charged plate.

[0118] 23. The system of claim 20 or any other claim, wherein the algae filter and dewatering device comprises a Coanda screen.

[0119] 24. The system of claim 1 or any other claim, further comprising a high sinuosity flow of the fluid flow in the downcomer configured to filter out heavier algae from the fluid flow.

[0120] 25. The system of claim 1 or any other claim, wherein the riser tower connected to the at least one downcomer tower produces a single photobioreactor system.

[0121] 26. The system of claim 25 or any other claim, further comprising a plurality of single photobioreactor systems connected together.

[0122] 27. The system of claim 26 or any other claim, wherein the plurality of single photobioreactor systems connected together each utilize a single algae-fluid input and a single mature algae output.

[0123] 28. The system of claim 26 or any other claim, further comprising a separate operational controller for each of the single photobioreactor systems when connected together.

[0124] 29. The system of claim 28 or any other claim, wherein the separate operational controllers are automatically controlled in response to sensor inputs from each single photobioreactor system.

[0125] 30. The system of claim 28 or any other claim, wherein the separate operational control devices include control of valves associated in each of the single photobioreactor systems and configured to open and close inputs and outputs for each single photobioreactor system.

[0126] 31. The system of claim 25 or any other claim, further comprising a horizontal piping section having the spiral pattern configured to provide the enhanced growth spectrum mixing, the horizontal piping section connected as part of the single photobioreactor system and configured to grow algae in a horizontal piping system.

[0127] 32. The system of claim 1 or any other claim, further comprising an integrated ethanol-corn-fertilizer-algae system configured to integrate the photobioreactor system with an industry selected from a fertilizer plant, a corn field, an ethanol plant, and any combination thereof.

[0128] 33. The system of claim 32 or any other claim, wherein the integrated ethanol-corn-fertilizer-algae system is configured to supply at least one by-product selected from carbon dioxide, ammonium effluent, stillage, and waste heat to the photobioreactor system.

[0129] 34. The system of claim 32 or any other claim, wherein the integrated ethanol-corn-fertilizer-algae system is configured to produce at least one product from the photobioreactor system selected from oil, a nutritional supplement, an organic fertilizer, astaxanthin, protein, and phycocyanin.

[0130] 35. The system of claim 1 or any other claim, further comprising an integrated coal or natural gas-wastewater-algae system configured to integrate the photobioreactor system with an industry selected from a wastewater treatment plant, a coal power plant, and a natural gas power plant.

[0131] 36. The system of claim 35 or any other claim, 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.

[0132] 37. The system of claim 36 or any other claim, wherein the integrated coal or natural gas-wastewater-algae system is configured to produce at least one product from the photobioreactor system selected from oil, a nutritional supplement, an organic fertilizer, astaxanthin, protein, and phycocyanin.

[0133] 38. A method of using a photobioreactor, the method comprising: providing at least one downcomer tower having a spiral pattern; using the vortex pattern to generate enhanced growth and spectral mixing in the downcomer column; connecting a riser tower to the at least one downcomer tower; inputting a fluid having algae into the at least one downcomer tower near an upper portion of the downcomer tower using a fluid input; generating an algae downward fluid flow in the downcomer tower; inputting gas into the riser tower near a bottom of the riser tower using a gas input; using the gas to drive system flow; generating an upward flow of gas in the riser column; inputting carbon dioxide into the at least one downcomer tower near a bottom of the downcomer tower using a carbon dioxide input; generating an upward flow of carbon dioxide gas in the downcomer column; generating a countercurrent flow with the algae downward fluid flow and the carbon dioxide gas upward flow in the downcomer tower; optimally reacting the algae and the carbon dioxide in the countercurrent flow; collecting mature algae from the downcomer tower in a collection tank; A method comprising:

[0134] 39. The method of claim 38 or any other claim, wherein optimally reacting the algae and the carbon dioxide in the counterflow comprises an appropriate amount of reaction time when mixing the algae and the carbon dioxide.

[0135] 40. The method of claim 38 or any other claim, wherein the at least one downcomer tower comprises at least two downcomer towers.

[0136] 41. The method of claim 40 or any other claim, wherein the at least two downcomer towers are each located outside the riser tower.

[0137] 42. The method of claim 38 or any other claim, further comprising using a vortex pattern in the riser tower to provide the enhanced growth mixing spectral mixing in the riser tower.

[0138] 43. The method of claim 38 or any other claim, further comprising generating gas bubbles using the carbon dioxide gas using a sparger located near the carbon dioxide gas input.

[0139] 44. The method of claim 43 or any other claim, wherein the gas bubbles have a gas bubble size selected from nanobubble size and microbubble size.

[0140] 45. The method of claim 38 or any other claim, wherein the fluid comprises nutrients.

[0141] 46. ​​The method of claim 45 or any other claim, further comprising filtering carbon dioxide from the gas using a filter located near the top of the riser tower.

[0142] 47. The system of claim 46 or any other claim, further comprising using a gas release to release other gases filtered from the gas, wherein the other gases are selected from nitrogen, oxygen, trace gases, and any combination thereof.

[0143] 48. The method of claim 38 or any other claim, wherein the gas is selected from carbon dioxide, air, flue gas, and gas from a chimney.

[0144] 49. The method of claim 46 or any other claim, further comprising circulating the filtered carbon dioxide to the bottom of the downcomer column using a gas circulation component.

[0145] 50. The method of claim 38 or any other claim, further comprising consuming the carbon dioxide using the reaction between the algae and the carbon dioxide in the counterflow.

[0146] 51. The method of claim 50 or any other claim, further comprising consuming substantially all of the carbon dioxide using the reaction between the algae and the carbon dioxide in the counterflow.

[0147] 52. The method of claim 38 or any other claim, wherein the tower is made from transparent tubing.

[0148] 53. The method of claim 46 or any other claim, wherein the filter is selected from a graphene filter, a membrane, a molecular filter, and a metal oxide framework filter.

[0149] 54. The method of claim 43 or any other claim, wherein the sparger comprises a fine mesh disk, a microbubble generator, or a nanobubble generator.

[0150] 55. The method of claim 38 or any other claim, further comprising adjusting the rate of the downward fluid flow in the downcomer column using a downward fluid flow rate regulator.

[0151] 56. The method of claim 38 or any other claim, further comprising adjusting the depth of the spiral pattern within the tower.

[0152] 57. The method of claim 38 or any other claim, further comprising filtering and dewatering mature algae in the downcomer tower using an algae filter and dewatering device near the bottom of the downcomer tower, and directing the filtered mature algae to the collection tank.

[0153] 58. The method of claim 38 or any other claim, further comprising coagulating mature algae in the downcomer tower using an algae coagulator near the bottom of the downcomer tower.

[0154] 59. The method of claim 58 or any other claim, wherein the algae coagulator comprises charged plates.

[0155] 60. The method of claim 57 or any other claim, wherein the algae filter and dewatering device comprises a Coanda screen.

[0156] 61. The method of claim 38 or any other claim, further comprising a high sinuosity flow of the fluid flow in the downcomer configured to filter out heavier algae from the fluid flow.

[0157] 62. The method of claim 38 or any other claim, wherein the riser tower connected to the at least one downcomer tower creates a single photobioreactor system.

[0158] 63. The method of claim 62 or any other claim, further comprising connecting a plurality of single photobioreactor systems together.

[0159] 64. The method of claim 63 or any other claim, wherein the connected multiple single photobioreactor systems each utilize a single algae-fluid input and a single mature algae output.

[0160] 65. The method of claim 63 or any other claim, further comprising a separate operational controller for each of the single photobioreactor systems when connected together.

[0161] 66. The method of claim 65 or any other claim, wherein the separate operational control devices are automatically controlled in response to sensor inputs from each single photobioreactor system.

[0162] 67. The method described in claim 65 or any other claim, wherein the separate operation control devices control associated valves in each of the single photobioreactor systems and control the opening and closing of inputs and outputs for each single photobioreactor system.

[0163] 68. The method of claim 62 or any other claim, further comprising providing a horizontal piping section having the spiral pattern to generate the enhanced growth mixture spectrum mixing, connecting the horizontal piping system as part of the single photobioreactor system, and growing algae in the horizontal piping system.

[0164] 69. The method of claim 38 or any other claim, further comprising integrating the photobioreactor system with an industry selected from a fertilizer plant, a corn field, an ethanol plant, and any combination thereof.

[0165] 70. The method of claim 69 or any other claim, further comprising supplying at least one by-product from the industry selected from carbon dioxide, ammonium effluent, stillage, and waste heat to the photobioreactor system.

[0166] 71. The method of claim 69 or any other claim, further comprising producing at least one product selected from oil, a dietary supplement, an organic fertilizer, astaxanthin, protein, and phycocyanin from the photobioreactor system.

[0167] 72. The method of claim 38 or any other claim, 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.

[0168] 73. The method of claim 72 or any other claim, further comprising supplying at least one by-product selected from effluent, carbon dioxide, electricity, and wastewater from the industry to the photobioreactor system.

[0169] 74. The method of claim 72 or any other claim, further comprising producing at least one product selected from oil, a nutritional supplement, an organic fertilizer, astaxanthin, protein, and phycocyanin from the photobioreactor system.

[0170] 75. The method of claim 57 or any other claim, further comprising circulating the fluid flow after the mature algae has filtered to the top of the downcomer.

[0171] 76. The method of claim 75 or any other claim, wherein the circulated fluid flow comprises immature algae, nutrients, fluids, and any combination thereof.

[0172] As can be readily understood from the foregoing, the basic concepts of various embodiments of the present invention can be embodied in a variety of ways, involving both bioreactor techniques and devices for implementing suitable bioreactors. The bioreactor techniques are disclosed herein as part of the results shown to be achieved by the various devices described, as well as steps that are inherent in their use. These are simply the natural results of utilizing the devices as intended and described. Additionally, while several devices are disclosed, it should be understood that these not only perform certain methods, but can also be varied in several ways. Importantly, with regard to all of the foregoing, all of these aspects should be understood to be encompassed by the present disclosure.

[0173] The discussion contained herein is intended to serve as a basic description. Readers should recognize that the specific discussion may not explicitly describe all possible embodiments, and many alternatives are implicit. It may not completely describe the general nature of various embodiments of the present invention, nor may it explicitly indicate how each feature or element may actually represent a broader function or a wide variety of alternative or equivalent elements. As an example, terms of degree, approximation, and / or relative terms may be used. These may include terms such as "substantially," "about," "only," and the like. These words and word types are to be understood in their dictionary sense as terms encompassing a sufficient or substantial amount, quantity, size, etc., and terms encompassing most, but not all, of what is specified. Furthermore, when or if used in connection with this application, terms of degree, approximation, and / or relative terms should also be understood to encompass more precise and even quantitative values, including various levels of precision, and the possibility of claims addressing several quantitative options and alternatives. For example, in the range ultimately used, the presence or absence of a substance or condition in a particular input, output, or particular step can be specified as substantially only x or substantially free of x, as a value of about x or other such similar language. As an example, when percentage values ​​are used, these types of terms should be understood to encompass percentage options including 99.5%, 99%, 97%, 95%, 92%, or even 90% of the stated value or relative term; and correspondingly, for values ​​at the other end of this range (e.g., substantially free of x), these should be understood to encompass percentage options including 0.5%, 1%, 3%, 5%, 8%, or even 10% or less of the stated value or relative term, all regardless of whether they may be defined as either a volume ratio or a weight ratio. In context, these should be understood by those skilled in the art as being disclosed and included, whether in an absolute value sense or in evaluating one substance or set of substances relative to the value of a second substance or set of substances.Again, these are implicitly included in the present disclosure and should (and would be) understood by one of ordinary skill in the art. Where this application is described in device-oriented terms, each element of the device implicitly performs a function. Not only may apparatus claims be included for the described device, but method or process claims may also be included to address the functionality of the embodiments and what each element performs. Neither the description nor the terminology is intended to limit the scope of the claims that may be included in any subsequent patent application.

[0174] It should also be understood that various modifications may be made without departing from the nature of various embodiments of the present invention. Such modifications are implicitly included in the description and still fall within the scope of various embodiments of the present invention. The broad disclosure, encompassing the explicit embodiments shown, the wide variety of implicit alternative embodiments, and the broad range of methods or processes, etc., is encompassed by this disclosure and may 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 may be pursued at a later date (such as by any required deadline) or if the applicant seeks a subsequent patent application based on this application. With this understanding, the reader should appreciate that the present disclosure is intended to support any subsequent patent application that may seek examination of as broad a claim basis as is deemed within the applicant's rights and that may be designed to result in a patent that covers multiple aspects of embodiments of the present invention, both independently and as an overall system.

[0175] Furthermore, each of the various elements of the embodiments of the invention and claims may also be achieved in a variety of ways. In addition, when used or implied, elements are to be understood as encompassing individual and multiple structures that may or may not be physically connected. The present disclosure should be understood to encompass each such variation, whether it be a variation of any apparatus, method, or process embodiment, or even simply a variation of any of these elements. In particular, as the present disclosure relates to elements of various embodiments of the invention, it should be understood that the words for each element may be expressed by equivalent apparatus or method terms, even if only the function or result is identical. Such equivalent, broader, or even more general terms should be considered encompassed in the description of each element or action. Such terms may be used instead when desired to make explicit the implicitly broad coverage enjoyed by embodiments of the invention. By way of example only, it should be understood that all actions may be expressed as a means for performing that action or as an element that causes that action. Similarly, each disclosed physical element should be understood to encompass a disclosure of the action that the physical element facilitates. With respect to this last aspect, by way of example only, any disclosure of "flowing" should be understood to encompass disclosure of the act of "flowing," whether or not explicitly discussed; conversely, if there is in fact a disclosure of the act of "flowing," such disclosure should be understood to encompass disclosure of "flowing" and even "means for flowing." Such variations and alternative terms are to be understood as being expressly included in the description. Moreover, each such means should be understood to encompass all elements that can perform a given function (whether or not explicitly described as such), and all descriptions of elements that perform a described function should be understood as non-limiting examples of means for performing that function.As another non-limiting example, it should be understood that claim elements may be expressed as any of components, programming, subroutines, logic, or elements that are configured or configured and arranged to provide or even achieve a particular result, use, object, state, function, or operation, or as components that are capable of accomplishing a particular activity, result, use, object, state, function, or operation, all of which should be understood within the scope of this disclosure and the descriptions written.

[0176] Any patents, publications, and other references mentioned in this patent application are incorporated herein by reference. Any priority cases claimed by this application are attached hereto and incorporated herein by reference. Additionally, for each term used, common dictionary definitions should be understood to be incorporated for each term, unless their use in this application contradicts a broadly supporting interpretation, and all definitions, alternative terms, and synonyms, as contained in the Random House Webster's Unabridged Dictionary, Second Edition, are understood to be incorporated herein by reference. Finally, all references listed in the list of references below or statements of any other information filed in this application are attached hereto and incorporated herein by reference; however, with respect to each of the above, to the extent that such information or statements incorporated by reference may be deemed inconsistent with the patenting of various embodiments of this invention, such statements shall not be deemed expressly made by the applicant.

[0177] (US Patent) [Table 1]

[0178] (US Patent Application Publication) [Table 2]

[0179] (Foreign patent application publication) [Table 3]

[0180] (Non-patent literature) [Table 4-1] [Table 4-2] [Table 4-3] [Table 4-4]

[0181] Accordingly, Applicant hereby grants to its assignee at least: i) each of the bioreactor devices as disclosed and described herein; ii) related methods as disclosed and described; iii) similar, equivalent, and even implicit variations of each of these devices and methods; iv) alternative designs thereof that perform each of the functions as disclosed and described and shown; v) alternative designs and methods thereof that perform each of the functions as disclosed and described and shown implicitly to perform; vi) each feature, component, and step shown as a separate and independent invention; vii) uses that are improved by the various systems or components disclosed; and viii) applications that are improved by such processes, methods, systems, or components. ix) each system, method, and element shown or described herein as applied to any specific field or device mentioned; x) methods and apparatus substantially as described above and with reference to any of the accompanying examples; xi) apparatus for carrying out the methods described herein, comprising means for performing the steps; xii) various combinations and permutations of each of the disclosed elements; xiii) each potentially dependent claim or concept as dependent on any and all of the presented independent claims or concepts; and xiv) all inventive embodiments described herein.

[0182] Additionally, with regard to computer aspects and aspects adaptable to programming or other electronic automation, when characterizing these and all other aspects of various embodiments of the present invention, whether characterized as devices, capabilities, elements, or otherwise, it should be understood that all of these may be implemented via software, hardware, or even firmware structures, as settings for general-purpose computers, programmed chips or chipsets, ASICs, application-specific controllers, subroutines, logic, or other known programmable or circuit-specific structures, and therefore all such aspects are defined at least by structures including hardware circuitry, firmware, programmed application-specific components, and even general-purpose computers programmed to perform the identified aspects, as those skilled in the art will clearly recognize. With respect to such items implemented by programmable features, Applicant claims at least: xv) a process performed with the aid of a computer, machine, or computing machine as described throughout the above discussion; xvi) a programmable apparatus as described throughout the above discussion; xvii) a computer readable memory encoded with data for instructing a computer comprising means or elements that function as described throughout the above discussion; xviii) a computer, machine, or computing machine configured as disclosed and described herein; xix) individual or combined subroutines, processor logic, and / or programs as disclosed and described herein; xx) a carrier medium carrying computer readable code for controlling a computer to perform any individual and combined method separately as described herein or in any claim; xxi) a computer program for performing any individual and combined method separately as disclosed; xxii) a computer program including all and each combination of means for performing any individual and combined steps as disclosed; xxiii) a storage medium storing each computer program disclosed;xxiv) signals carrying the disclosed computer programs; xxv) processors executing instructions that operate to accomplish the recited steps and activities; xxvi) circuitry (including configurations of transistors, gates, etc.) that act in sequence and / or cause actions as recited; xxvii) computer-readable media storing instructions for performing the recited steps and causing activities; xxviii) related methods disclosed and described; xxix) similar, equivalent, and even implicit variations of each of these systems and methods; xxx) alternative designs thereof that perform each of the functions as disclosed and described; xxxi) alternative designs and methods thereof that perform each of the functions as implicitly shown to perform those disclosed and described; xxxii) each feature, component, and step shown as a separate and independent invention; and xxxiii) in addition, claims should be understood to support and describe the invention as to various combinations of each of the above and any aspects, all without limiting any other aspect.

[0183] With respect to claims, whether presented for examination now or later, it should be understood that, for practical reasons and to avoid significantly expanding the examination burden, applicant may, at any time, present only the first claim, or perhaps only the first claim accompanied by only the first dependent claim. The Office and any third party interested in the potential scope of this or any subsequent application should understand that broader claims may be presented later in this case, in a case claiming the benefit of this case, or in any continuing application, regardless of any preliminary amendments, other amendments, claim language, or arguments presented, and that, therefore, there is no intention to abandon or abandon any potential subject matter throughout the pendency of any case. It should be understood that if or when broader claims are presented, this is possible to the extent that any amendments, claim language, or arguments presented in this or any subsequent application are deemed to be made to avoid such prior art, and that such may require that any relevant prior art that may have been considered at any time prior thereto may need to be revisited, as such reason may be precluded by later presented claims, etc. Both examiners and any other individuals interested in existing or later potential coverage, or considering at any time any possibility of directing a waiver or assignment of potential coverage, should recognize that no such assignment or waiver is intended or will ever exist in this or any subsequent application. Limitations such as those set forth in Hakim v. Cannon Avent Group, PLC, 479 F.3d 1313 (Fed. Cir (2007)), etc., are expressly not intended in this or any related matter. Additionally, support, to the extent required under new matter law (including, but not limited to, Article 123(2) of the European Patent Convention and 35 U.S.C. 132 or other such law), should be understood to permit the addition of any of various dependent claims or other elements presented under one independent claim or concept as dependent claims or elements under any other independent claim or concept.It should also be understood that when drafting any claim at any time, whether in this application or any subsequent application, Applicant intends to achieve as complete and broad a coverage as legally possible. Applicant may simply not be able to anticipate all possible events, and so, to the extent that insufficient substitution has been made, Applicant has not actually drafted any claim to literally encompass any particular embodiment, and to the extent otherwise applicable, Applicant should not be understood as somehow intending or actually assigning such coverage, and one of ordinary skill in the art should not be reasonably expected to have drafted a claim that would literally encompass such alternative embodiment.

[0184] Additionally, where or when used, the use of the transitional phrases "comprising," "including," "containing," "characterized by," and "having" are used to preserve the "open-ended" claims herein in accordance with conventional claim interpretation, including that discussed in MPEP §2111.03. Thus, unless the context requires otherwise, it will be understood that the terms "comprise" or "comprises" or "comprising", variations such as "include" or "includes" or "including", variations such as "contain" or "contains" and "containing", variations such as "characterized by" or "characterizing by", variations such as "have" or "has" or "having", etc. 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 that the applicant is legally entitled to the broadest coverage. Use of the phrase "or any other claim" is used to provide support for any claim that depends on any other claim, such as another dependent claim, another independent claim, a previously enumerated claim, a subsequently enumerated claim, etc. As one clarifying example, if a claim depends on "claim 9 or any other claim," etc., it could be rephrased as depending on claim 1, claim 8, or even claim 11, if such exist, as desired, and still fall within the present disclosure.It will be understood that this phrase also provides support for any combination of elements in the claims, and further incorporates any desired appropriate antecedent for a given claim combination, such as with method, apparatus, process, etc. claim combinations.

[0185] Finally, any claim set forth at any time is incorporated herein by reference as part of this description of various embodiments of the application, and Applicant expressly reserves the right to use all or a portion of such incorporated content of such claim as additional description in support of any or all of the claim or any element or component thereof, and Applicant further expressly reserves the right, as appropriate, to move any portion or all of the incorporated content of such claim or any element or component thereof from the description to the claim (or vice versa), to define the matter sought to be protected by this application or by any subsequent continuation, divisional, or continuation-in-part application thereof, or to obtain any benefit of, or comply with, any national or treaty patent laws, rules, or regulations, and such incorporated-by-reference content shall survive the entire pendency of this application, including any subsequent continuation, divisional, or continuation-in-part application thereof, or any reissue or extension thereto.

Claims

1. 1. A photobioreactor system, comprising: at least one downcomer tower having a spiral pattern, said spiral pattern configured to provide enhanced growth mixing spectral mixing in said downcomer tower; a riser tower connected to the at least one downcomer tower; an algae-fluid input configured to input a fluid having algae into the at least one downcomer tower near an upper portion of the downcomer tower, the algae-fluid input configured to generate an algae downward fluid flow in the downcomer tower; and a gas input configured to input gas into the riser tower near a bottom of the riser tower, the gas input configured to generate an upward flow of gas in the riser tower and drive system flow; a carbon dioxide gas input configured to input carbon dioxide into the at least one downcomer tower near a bottom of the downcomer tower, the carbon dioxide gas input configured to generate an upward flow of carbon dioxide gas in the downcomer tower; a countercurrent flow created with the algae downward fluid flow and the carbon dioxide gas upward flow in the downcomer tower, the countercurrent flow configured to allow optimal reaction between the algae and the carbon dioxide; a collection tank configured to collect mature algae from the downcomer tower; A system comprising:

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

3. The system of claim 1 , wherein the at least one downcomer tower comprises at least two downcomer towers.

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

5. 10. The system of claim 1, wherein the riser tower comprises the spiral pattern configured to provide the enhanced growth and spectral mixing in the riser tower.

6. 10. The system of claim 1, further comprising a sparger proximate the carbon dioxide gas input and proximate a bottom of the downcomer tower, the sparger configured to generate gas bubbles with the carbon dioxide gas.

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

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

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

10. 10. The system of claim 9, further comprising a gas release configured to release other gases filtered from the gas, the other gases 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 chimney gas.

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

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

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

15. The system of claim 1 , wherein the tower is made from transparent tubing.

16. 10. The system of claim 9, wherein the filter is selected from a graphene filter, a membrane, a molecular filter, and a metal oxide framework filter.

17. 7. The system of claim 6, wherein the sparger comprises a fine mesh disk, a microbubble generator, or a nanobubble generator.

18. The system of claim 1 , further comprising a downward fluid flow rate regulator configured to regulate a rate of the downward fluid flow in the downcomer tower.

19. The system of claim 1 , further comprising a spiral adjuster configured to adjust the depth of the spiral in the tower.

20. 10. The system of claim 1, further comprising an algae filter and dewatering device near the bottom of the downcomer tower, the algae filter and dewatering device configured to filter mature algae in the downcomer tower, remove water from the mature algae, and direct the filtered mature algae to the collection tank.

21. 10. The system of claim 1, further comprising an algae coagulator near the bottom of the downcomer tower configured to coagulate mature algae in the downcomer tower.

22. 22. The system of claim 21, wherein the algae coagulator comprises a charged plate.

23. 21. The system of claim 20, wherein the algae filter and dewatering device comprises a Coanda screen.

24. 10. The system of claim 1, further comprising a high sinuosity flow of the fluid flow in the downcomer configured to filter out heavier algae from the fluid flow.

25. 10. The system of claim 1, wherein the riser tower connected to the at least one downcomer tower creates a single photobioreactor system.

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

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

28. 27. The system of claim 26, further comprising a separate operational controller for each of the single photobioreactor systems when connected together.

29. 30. The system of claim 28, wherein the separate operational controllers are automatically controlled in response to sensor inputs from each single photobioreactor system.

30. 30. The system of claim 28, wherein the separate operational control devices comprise controls for associated valves in each of the single photobioreactor systems, the valve controls configured to open and close inputs and outputs for each single photobioreactor system.

31. 26. The system of claim 25, further comprising a horizontal piping section having the spiral pattern configured to provide the enhanced growth spectrum mixing, the horizontal piping section being connected as part of the single photobioreactor system and configured to grow algae in the horizontal piping system.

32. 10. The system of claim 1, further comprising an integrated ethanol-corn-fertilizer-algae system, wherein the integrated ethanol-corn-fertilizer-algae system is configured to integrate the photobioreactor system with an industry selected from a fertilizer plant, a corn field, an ethanol plant, and any combination thereof.

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

34. 33. The system of claim 32, wherein the integrated ethanol-corn-fertilizer-algae system is configured to produce at least one product from the photobioreactor system selected from oil, a nutritional supplement, an organic fertilizer, astaxanthin, protein, and phycocyanin.

35. 10. The system of claim 1, further comprising an integrated coal or natural gas-wastewater-algae system, wherein the integrated coal or natural gas-wastewater-algae system is configured to integrate the photobioreactor system with an industry selected from a wastewater treatment plant, a coal power plant, and a natural gas power plant.

36. 36. The system of 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. 37. The system of claim 36, wherein the integrated coal or natural gas-wastewater-algae system is configured to produce at least one product from the photobioreactor system selected from oil, a nutritional supplement, an organic fertilizer, astaxanthin, protein, and phycocyanin.

38. 1. A method of using a photobioreactor, the method comprising: providing at least one downcomer tower having a spiral pattern; generating enhanced growth and spectral mixing in the downcomer column using the vortex pattern; connecting a riser tower to the at least one downcomer tower; inputting an algae-bearing fluid into the at least one downcomer tower near an upper portion of the downcomer tower using a fluid input; generating an algae downward fluid flow in the downcomer tower; inputting gas into the riser tower near a bottom of the riser tower using a gas input; driving system flow with the gas; generating an upward flow of gas in the riser column; inputting carbon dioxide into the at least one downcomer tower near a bottom of the downcomer tower using a carbon dioxide input; generating an upward flow of carbon dioxide gas in the downcomer column; generating a countercurrent flow with the algae downward fluid flow and the carbon dioxide gas upward flow in the downcomer tower; optimally reacting the algae with the carbon dioxide in the counterflow; collecting mature algae from the downcomer tower in a collection tank; A method comprising:

39. 39. The method of claim 38, wherein optimally reacting the algae and the carbon dioxide in the counterflow comprises an appropriate amount of reaction time in mixing the algae and the carbon dioxide.

40. 39. The method of claim 38, wherein the at least one downcomer tower comprises at least two downcomer towers.

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

42. 39. The method of claim 38, further comprising using a swirl pattern in the riser tower to provide the enhanced growth mixing spectral mixing in the riser tower.

43. 39. The method of claim 38, further comprising generating gas bubbles with the carbon dioxide gas using a sparger located near the carbon dioxide gas input.

44. 44. The method of claim 43, wherein the gas bubbles have a gas bubble size selected from nanobubble size and microbubble size.

45. 39. The method of claim 38, wherein the fluid comprises nutrients.

46. 46. ​​The method of claim 45, further comprising filtering carbon dioxide from the gas with a filter located near the top of the riser tower.

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

48. 39. The method of claim 38, wherein the gas is selected from carbon dioxide, air, flue gas, and chimney gas.

49. 47. The method of claim 46, further comprising recycling the filtered carbon dioxide to the bottom of the downcomer column using a gas circulation component.

50. 39. The method of claim 38, further comprising consuming the carbon dioxide using the reaction between the algae and the carbon dioxide in the counterflow.

51. 51. The method of claim 50, further comprising consuming substantially all of the carbon dioxide using the reaction between the algae and the carbon dioxide in the counterflow.

52. 39. The method of claim 38, wherein the tower is made from transparent tubing.

53. 47. The method of claim 46, wherein the filter is selected from a graphene filter, a membrane, a molecular filter, and a metal oxide framework filter.

54. 44. The method of claim 43, wherein the sparger comprises a fine mesh disk, a microbubble generator, or a nanobubble generator.

55. 39. The method of claim 38, further comprising adjusting the velocity of the downward fluid flow in the downcomer column with a downward fluid flow velocity regulator.

56. 39. The method of claim 38, further comprising adjusting the depth of the spiral pattern in the tower.

57. 39. The method of claim 38, further comprising filtering and dewatering mature algae in the downcomer tower using an algae filter and dewatering device near the bottom of the downcomer tower and directing the filtered mature algae to the collection tank.

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

59. 59. The method of claim 58, wherein the algae coagulator comprises a charged plate.

60. 58. The method of claim 57, wherein the algae filter and dewatering device comprises a Coanda screen.

61. 39. The method of claim 38, further comprising: a high sinuosity flow of the fluid flow in the downcomer configured to filter out heavier algae from the fluid flow.

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

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

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

65. 64. The method of claim 63, further comprising a separate operational controller for each of the single photobioreactor systems when connected together.

66. 66. The method of claim 65, wherein the separate operational controllers are automatically controlled in response to sensor inputs from each single photobioreactor system.

67. 66. The method of claim 65, wherein the separate motion controllers control associated valves in each of the single photobioreactor systems to control the opening and closing of inputs and outputs for each single photobioreactor system.

68. 63. The method of claim 62, further comprising providing a horizontal piping section having the spiral pattern that produces the enhanced growth mixture spectrum mixing, connecting the horizontal piping system as part of the single photobioreactor system, and growing algae in the horizontal piping system.

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

71. 70. The method of claim 69, further comprising producing at least one product selected from oil, a nutritional supplement, an organic fertilizer, astaxanthin, protein, and phycocyanin from the photobioreactor system.

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

74. 73. The method of claim 72, further comprising producing at least one product selected from oil, a nutritional supplement, an organic fertilizer, astaxanthin, protein, and phycocyanin from the photobioreactor system.

75. 58. The method of claim 57, further comprising circulating the fluid flow after the mature algae has filtered to the top of a downcomer.

76. 76. The method of claim 75, wherein the circulated fluid flow comprises immature algae, nutrients, fluids, and any combination thereof.

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