Microalgae Bioreactor with Tiltable Grates for Integrated Harvesting
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Solution Overview
Problem
Existing bioreactors for microalgae production and harvesting are costly, complex, inefficient, and prone to contamination, requiring large areas and poor infrastructure, with separate systems for production and harvesting that are difficult to maintain and operate.
Innovation Solution
A compact, closed bioreactor system that integrates production and harvesting using a rotating beam with tiltable mixing and harvesting grates, equipped with a transparent glass or plastic roof for light penetration, and a floating construction for efficient seawater CO2 utilization, allowing for continuous operation and oxygen compression for additional product generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate systems for production and harvesting are used, then the functions can be performed independently, but the device complexity and cost increase significantly
Solution Approach 1:
The patent combines production and harvesting functions into a single integrated bioreactor system. The rotating beam with mixing grates performs both cultivation mixing and harvesting operations sequentially, eliminating the need for separate production and harvesting systems. This reduces overall device complexity while maintaining functional versatility through temporal separation of operations.
Solution Approach 2:
The rotating beam assembly serves multiple functions: it acts as a mixing mechanism during production phases and as a harvesting mechanism when grates are tilted to skim the algal layer. This multi-functional design eliminates the need for separate dedicated equipment, reducing system complexity while maintaining adaptability for different operational modes.
2Illumination intensity
If large area open systems are used for production, then light availability is improved, but contamination risk and infrastructure requirements increase
Solution Approach 1:
The bioreactor employs a transparent dome-shaped cover that allows maximum light penetration to the algal culture while creating a closed system. This thin film structure provides mechanical protection and seals the system to prevent contamination from external sources, simultaneously maintaining high illumination intensity for photosynthesis.
Solution Approach 2:
The closed bioreactor system creates a controlled internal environment that protects the algal culture from external contaminants. The sealed structure with controlled access points maintains a stable, contamination-free atmosphere while allowing sufficient light transmission for photosynthetic activity.
3Productivity
If complex harvesting mechanisms are used, then harvesting efficiency is improved, but maintenance cost and operational difficulty increase
Solution Approach 1:
The harvesting grates are designed to be tiltable relative to the rotating beam, allowing dynamic adjustment between horizontal (for mixing) and tilted (for harvesting) positions. This dynamic configuration enables the same structure to perform both mixing and harvesting functions, improving harvesting efficiency without requiring complex separate mechanisms, thereby reducing maintenance and operational complexity.
4Quantity of substance
If open systems are used for CO2 supply, then CO2 availability is improved, but contamination and infrastructure requirements worsen
Solution Approach 1:
The closed bioreactor system provides a controlled environment for CO2 supply, allowing precise dosing through the sealed structure. CO2 can be introduced through the headspace or dissolved in water phases without exposing the culture to external contaminants. This maintains high CO2 availability while preventing contamination that would occur with open systems.
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 efficient, continuous, and hygienic microalgae production and harvesting with reduced maintenance and operational costs, enabling the production of algal oil and oxygen, suitable for various industries, while meeting ergonomic and safety standards.
Implementation Method 1
a compact, closed bioreactor system that integrates production and harvesting using a rotating beam with tiltable mixing and harvesting grates, equipped with a transparent glass or plastic roof for light penetration
Implementation Method 2
a rotating beam with tiltable mixing and harvesting grates
Implementation Method 3
a rotating beam with tiltable mixing and harvesting grates
Data Source
Figure 1~2
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Figure 5~6
AI summary
A bioreactor (30) for production and harvesting of microalgae is described, comprising a reactor basin (32) in the form of a tank arranged to receive CO2 and water as well as algae, and which is equipped with at least one outlet for harvesting of algal biomass, where the reactor basin (32) comprises a rotating beam (54) equipped with one or more tiltable mixing grates (60) and harvesting grates (62).