Bioreactor Atomizer for Algae Nutrient Mist and CO2 Delivery
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Solution Overview
Problem
Current methods for growing algae, such as open ponds and photobioreactors, face challenges including high water and energy consumption, contamination, low biomass concentration, and inefficiencies in nutrient utilization and harvesting, making them economically unfeasible for large-scale commercial production.
Innovation Solution
A closed bioreactor system with a substrate for algae growth, utilizing a nutrient mist created by an atomizer that combines liquid nutrients with CO2, and a harvesting mechanism that allows for efficient removal of algae without exposure to water, featuring a substrate with micro-scale geometric features for enhanced growth and a relief valve for excess oxygen, enabling scalable and energy-efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If open ponds are used for algae cultivation, then large-scale production is possible, but water loss to evaporation is substantial and CO2 utilization is inefficient
Solution Approach 1:
The patent employs a thin film support structure (membrane or porous substrate) that allows algae to grow as a biofilm. This thin film configuration enables large surface area for photosynthesis while being contained in a closed system, preventing evaporation losses while maintaining scalability.
Solution Approach 2:
The patent creates a controlled atmosphere within the bioreactor, using a closed system that prevents water evaporation to the external environment. The headspace is managed to optimize CO2 concentration for algae growth while preventing water loss, effectively creating a controlled inert environment regarding water vapor exchange.
2Reliability
If photobioreactors are used for algae cultivation, then contamination and evaporation problems are overcome, but oxygen buildup inhibits algae growth and requires degassing zones
Solution Approach 1:
The patent extracts or removes oxygen from the bioreactor headspace periodically or continuously through sparging with inert gas (nitrogen or carbon dioxide). This extracts the harmful oxygen buildup without requiring a complex degassing zone, maintaining a controlled atmosphere that prevents contamination while removing excess oxygen.
Solution Approach 2:
The patent uses gas sparging (pneumatic method) where inert gas is bubbled through the algae culture or headspace to strip out excess oxygen. This pneumatic approach to oxygen removal is simpler than mechanical degassing zones and effectively maintains optimal oxygen levels for algae growth.
3Ease of operation
If water-based systems are used for algae growth, then nutrients are easily delivered, but harvesting requires energy intensive centrifuging and filtering
Solution Approach 1:
The patent uses a thin film support structure that allows the algae biofilm to be physically separated from the bulk nutrient solution. Harvesting is achieved by simply removing or detaching the thin film substrate containing the algae, eliminating the need for energy-intensive centrifugation or filtration processes while maintaining easy nutrient delivery through the liquid medium.
Solution Approach 2:
The patent segments the algae culture by growing it as a discrete biofilm on a support substrate rather than as suspended cells in water. This segmentation allows the algae to be harvested as a unified thin film layer, separating the harvesting operation from the bulk liquid volume and dramatically reducing energy requirements.
4Productivity
If nebulized nutrient fog is used for algae growth, then nutrient assimilation is improved and volume efficiency increases, but surface tension effects make nebulization difficult
Solution Approach 1:
The patent employs a nebulizer device that uses pneumatic principles to atomize liquid nutrients into a fine fog or mist. Compressed gas (typically air or nitrogen) is used to break up the liquid nutrient stream into droplets, creating a nebulized fog that is easily assimilated by the algae while overcoming surface tension effects through sufficient gas pressure and proper nozzle design.
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
The system achieves lower energy consumption, reduced nutrient input, improved biomass concentration, and efficient harvesting, facilitating cost-effective and scalable commercial production of algae while maintaining hygienic conditions.
Implementation Method 1
an atomizer fluidly connected between the bioreactor chamber and the liquid nutrient container and comprising a carbon dioxide inlet fluidly connected to receive a source of carbon dioxide wherein the atomizer is configured to receive liquid nutrient from the liquid nutrient container and produce a liquid nutrient mist and provide a mixture of the liquid nutrient and the carbon dioxide
Implementation Method 2
Cyanobacteria are also able to convert solar energy at high rates into selected energy sources such as lipids and bio-hydrogen
Implementation Method 3
a relief valve for excess oxygen
Data Source
AI summary
An apparatus for growing biological material, comprising a bioreactor chamber comprising at least one substrate positioned within an interior of the bioreactor chamber to support the growth of the biological material; at least one inlet to supply nutrient; and at least one outlet configured to enable biological material to be retrieved from the bioreactor chamber; a liquid nutrient container comprising at least one liquid nutrient outlet fluidly connected to the bioreactor chamber to supply a liquid nutrient; and an atomizer fluidly connected between the bioreactor chamber and the liquid nutrient container and comprising a carbon dioxide inlet fluidly connected to receive a source of carbon dioxide wherein the atomizer is configured to receive liquid nutrient from the liquid nutrient container and produce a liquid nutrient mist and provide a mixture of the liquid nutrient and the carbon dioxide from the carbon dioxide inlet to the bioreactor chamber.