Helical Photobioreactor for Chlorella Growth and Refinement

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Solution Overview

Problem

Existing microalgae cultivation methods face challenges in optimizing growth conditions, nutrient delivery, and efficient separation and refinement of microalgae for high-value applications, particularly in producing Chlorella, which affects the quality and consistency of final products.

Innovation Solution

A photobioreactor with a helical glass structure for optimized sunlight exposure, integrated nutrient chambers, and CO2 injection, combined with a classifier system for precise separation and a pressurized liquid extraction (PLE) method for chlorophyll removal, followed by infrared drying and grinding to produce a refined microalgae powder.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If mass production techniques in large circular artificial ponds are used, then production volume is increased, but growth condition optimization and nutrient delivery efficiency deteriorate

Engineering Contradiction:

Improveproduction volumeVSAvoidgrowth condition optimization

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The large circular pond is segmented into multiple modular photobioreactor units with helical glass structures. Each module can be independently controlled for nutrient delivery, light exposure, and temperature, allowing optimization of growth conditions while maintaining high production volume through parallel operation of multiple segments.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from two-dimensional surface cultivation in ponds to three-dimensional helical tubular structures. This vertical dimensionality increase allows for optimized sunlight exposure through the helical configuration, improved nutrient delivery via integrated chambers, and enhanced mass transfer while maintaining high productivity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of manufacture

If conventional cultivation methods are used, then production cost is reduced, but separation and refinement efficiency deteriorates

Engineering Contradiction:

Improveproduction costVSAvoidseparation and refinement efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The system combines cultivation, classification, and refinement functions into an integrated photobioreactor system. The classifier system with mesh screens is directly integrated with the photobioreactor modules, allowing continuous separation and refinement without additional processing steps, thereby improving efficiency while maintaining cost-effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system implements continuous cultivation, continuous classification, and continuous refinement operations. The classifier system operates continuously to separate microalgae by size, and the refinement process continuously produces high-quality powder product, eliminating batch processing interruptions and improving overall productivity.

Inventive Principle:

Principle #20Continuity of useful action

3Device complexity

If traditional separation methods are used, then equipment complexity is reduced, but product quality and consistency deteriorates

Engineering Contradiction:

Improveequipment complexityVSAvoidproduct quality and consistency

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The system uses multiple identical photobioreactor modules with standardized helical glass structures and integrated classifier systems. This modular replication ensures consistent product quality across different production units while maintaining relatively simple individual module designs, achieving high manufacturing precision through standardization rather than complex single-unit designs.

Inventive Principle:

Principle #26Copying

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

Enhances microalgae growth efficiency, maintains optimal growth conditions, ensures high-quality separation and refinement, and produces a stable, high-value microalgae powder suitable for various industries.

Implementation Method 1

A photobioreactor with a helical glass structure for optimized sunlight exposure

Methodology Applied

Scientific EffectPhotosynthesis: Photosynthesis

Implementation Method 2

a pressurized liquid extraction (PLE) method for chlorophyll removal

Methodology Applied

Scientific EffectPressurized liquid extraction: Supercritical Fluid Extraction

Implementation Method 3

infrared drying and grinding to produce a refined microalgae powder

Methodology Applied

Scientific EffectInfrared radiation: Infrared Radiation

Data Source

PatentUS20260028564A1Microalgae cultivation photobioreactor with the ability to classify the cultivated algae and refine the final product for use in animal and poultry food compounds and human food additives

Publication Date: 2026.01.29 HAJIBARATI MAJID

AI summary

The present invention relates to a photobioreactor designed for the cultivation of microalgae, specifically the microalga Chlorella, with applications in animal and poultry feed as well as human food additives. This invention falls within the fields of microbiology, food preparation, human and animal nutrition, and agricultural industry practices. The photobioreactor is engineered to enable cost-effective mass production of microalgae by incorporating systems for injecting micronutrients into the culture medium. Additionally, the invention includes a classification system for sorting the produced microalgae and a refinement process for preparing the classified microalgae as a final product suitable for use in various nutritional compounds.