Algae-Based Polymer Production via Alkenone Conversion

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Solution Overview

Problem

The increasing market prices of petroleum and natural gas due to depletion, economic growth, and environmental concerns have created a need for polymer production methods that do not rely on fossil fuels.

Innovation Solution

Producing polymers from algae by culturing alkenone-producing algae species, such as Isochrysis galbana, under specific growth conditions, chemically modifying the alkenones, and polymerizing them to create hydrocarbons or biofuels like diesel, gasoline, syngas, and synthetic hydrocarbon gases, or directly converting algae into methane via hydrothermal gasification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If petroleum and natural gas are used as feedstocks for polymer production, then polymers with excellent processability, chemical resistance, and mechanical properties can be produced, but the production method relies on depleting fossil fuels with increasing market prices and environmental concerns

Engineering Contradiction:

Improvepolymer production methodVSAvoidfossil fuel dependence

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent changes the fundamental parameter of feedstock source from fossil fuels (petroleum and natural gas) to renewable biological sources (algae, plants, and microorganisms). This parameter change enables polymer production that is independent of depleting fossil fuel reserves while maintaining the ability to produce polymers with desirable properties through selective breeding and fermentation process optimization.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs microorganisms and algae that naturally produce polyhydroxyalkanoates (PHAs) and other polymers as part of their metabolic processes. By providing these organisms with appropriate nutrients and growth conditions, they self-produce the polymer materials needed, eliminating dependence on fossil fuel extraction and refining processes.

Inventive Principle:

Principle #25Self-service

2Reliability

If fossil fuels are used for polymer production, then established industrial processes are available, but market prices are increasing due to depletion, economic growth, and environmental concerns

Engineering Contradiction:

Improvepolymer production processVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent establishes continuous fermentation processes where microorganisms continuously convert renewable feedstocks (such as sugars from plants or waste materials) into polymers. This continuous production method provides reliable, scalable manufacturing that can sustain long-term operation without the price volatility associated with fossil fuel markets.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent uses microorganisms and algae as biological intermediaries that convert renewable raw materials into polymer products. These biological mediators perform the transformation function that previously required chemical refining of fossil fuels, providing a reliable production pathway that uses renewable resources and avoids fossil fuel price increases.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If new polymer production methods from algae are developed, then fossil fuel independence is achieved, but the process requires culturing algae under specific growth conditions and chemical modification steps

Engineering Contradiction:

Improverenewable feedstock usageVSAvoidproduction process

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent selects algae species and microorganisms that can grow in diverse environments (freshwater, saltwater, wastewater) and convert various carbon sources (sugars, organic waste, CO2) into polymers. This multi-functionality reduces the need for complex, specialized cultivation infrastructure while maintaining renewable feedstock independence.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent extracts and isolates the polymer products (such as PHAs) from the biological material after fermentation, then processes them into usable forms. This extraction approach separates the polymer production function from the complex biological cultivation process, simplifying the overall manufacturing workflow while maintaining renewable feedstock benefits.

Inventive Principle:

Principle #2Taking out (Extraction)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method provides a sustainable and efficient way to produce polymers and biofuels, reducing dependence on fossil fuels and offering a renewable alternative with algae capable of high lipid and alkenone production, thereby addressing the need for fossil fuel-independent polymer production.

Implementation Method 1

culturing an alkenone-producing alga under a growth condition sufficient to produce alkenones within the alga

Methodology Applied

Scientific EffectPhotosynthesis: Photosynthesis

Implementation Method 2

The alkenones may be converted to hydrocarbons by catalytic hydroprocessing

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 3

algae are directly converted into methane via hydrothermal gasification

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Data Source

PatentUS9879288B2Use of marine algae for producing polymers

Publication Date: 2018.01.30 MARINE BIOLOGICAL LAB

AI summary

In certain aspects, the disclosure provides methods for producing polymers from alkenone-producing algae, such as algae species of the Isochrysis family.