Patent Application
20240228922
The system comprises the inclusion of an algae growth medium. The algae growth medium may comprise algae content, nutrients, and water. Exemplary mediums include BG-11 for cyabobacteria and freshwater algae and F/2 for marine algae. Nutrient solutions may be infused with nitrogen, phosphorus, and/or other elements. The nutrients may include various minerals or materials which are necessary or beneficial for algae growth. Additional supplements, such as vitamins and growth enhancers may be added. The concentrations of these elements will be selected based on the desired algae composition and may be modified by the addition of additional water or by dehydration. The pH levels, generally varying between 6.5 to 8.5, may similarly be selected and controlled based on the desired algae composition. Sterilization may be achieved through autoclaving or filtration. The algae growth medium parameters may be tested prior to the introduction of algae content.
The algae content may include one or more species or sub-species of algae, including diatom, marimo, wakame, green algae, golden algae, Irish Moss, giant kelp, hijiki, latok, sea lettuce, arame, kombu, etc. The algae content selected may be supplied via laboratory or commercial suppliers, or in-house to the technology described herein. The algae content may be entered into the medium via inoculation or similar techniques. The algae content may be pipetted and then slowly mixed into the medium, although gross industrial inoculation techniques may also be utilized.
The algae may be fermented to yield alcohol (ethanol) for drink or fuel. Algae for algae-as-alcohol may be selected for high carbohydrate and starch content, and enzymatic hydrolysis may be used to breakdown the same into simple sugars. They may be inoculated with yeast (Saccharomyces cerevisiae) to ferment the sugar into ethanol.
The algae may also be processed as a textile or as textile pulp. The algae may be processed as pigmentation or media for beauty products, including makeup, (nutrients in) moisturizer, shampoo, conditioner, etc.
The system comprises a closed loop algae-water circulation track for circulating an aquatic algae growth medium. Circulation of material through the circulation track may be achieved through gravity, sloped tracks, siphoning, static mixers, baffles, cascades, automated valves, submersible pumps, inline pumps, variable speed pumps, air lifts, diffusers, propellers or impellers, paddle wheels, and using techniques such as flow control, programmed automation of pumps, valves, and mixers, etc., pulsed flow techniques such as intermittent pumping, and hydrodynamic flow modelling software. The track may consist of pipes, tubes, or other fluid flow conveyors. The track may be open or close-top. If the track is close-top, the top may be opaque or transparent, and may be made of glass, plastic, stainless steel, or any other material identified as comprising the segments, below. A closed-top may be helpful in ensuring controlled production, but an open-top may be employed to capture atmospheric benefits.
The system may comprise an external controller. The controller may be one or more computers, and may comprise a display device and one or more input devices. The controller may be a dedicated device, or conventional desktop or laptop computer, or a mobile device such as a smart phone. The controller is configured to receive instructions from the user pertaining to various system components. The external controller may receive, display, initiate, and control sensor data detection, load site, harvesting, cycle, kill, flush, and sanitization events, schedules, programs, and parameterizations. In particular, the external controller may enable a user to view and execute environmental monitoring, automation, nutrient dosing, aeration control, flow regulation, harvesting times, connectivity and remote access (such as via Wi-Fi), cleaning and maintenance, and emergency protocols.
The system may comprise a processor. The processor may be one or more computers, and may be a dedicated device, or conventional desktop or laptop computer, or a mobile device such as a smart phone. The processor may be separate from or combined with the external controller. The processor may receive feedback from the various system sensors, and convey instructions received from the external controller and relay the instructions to various system components. The processor may be programmed to automatically transmit instructions based on sensor feedback parameters. The processor may run one or more software applications in order to process system data.
The system may comprise a load site, which is a mechanism disposed on the track and configured to load the track with the load items, such as algae growth media, algae content, nutrients, minerals, vitamins, carbon dioxide, oxygen, and water. In one variation, a plurality of load sites are disposed throughout the track. In another variation, each load site is dedicated to a sub-set of load items.
The load site mechanism may consist of one or more tangent tracks and load capsule. The tangent tracks may each be in fluid communication with the primary track, with fluid communication controlled via one or more gates. The load capsule may be a container pre-loaded with load items and configured to fit snugly into a tangent track receiving vessel. In one variation, each load site is dedicated to receiving a separate load capsule type.
The load site mechanism may be configured to release a discrete unit of resources via the load capsule, or a steady stream of resources via the fluid flow of (aerated) gas or liquid. The load site mechanisms for fluid flow may consist of nozzle matrices distributed through the track or track segments. The resources for either the load capsules or non-discrete loading may be stored in dedicated or mixed reservoirs, with these reservoirs having their own sensors and load sites to prep the resources for content and concentration.
The load site mechanism may be in communication with the processor, such that loading occurs upon receiving instructions from the processor.
The system may comprise sets of live or dormant algae contained in load capsules or in reservoirs, and then upon receiving instructions pertaining to a given species of algae, load the designated algae at the load site. The load capsules may be designated using a code and may be stored in a matrix so that similar conditions may be applied to algae in load capsules throughout the load capsule matrix. In one embodiment, the load capsule matrix may be or disposed on a rotating disc or gear, with the load capsules occupying positions on the circumference or spokes on the gear, thereby enabling a designated load capsule to engage with the load site rotation of the disc or gear. In another embodiment, the load capsule matrix is disposed on a rail, with the rail configured to slide or otherwise move along an axis adjacent to the load site in order to allow for closer adjacency of the designated load capsule to the load site. In yet another embodiment, the load matrix is a grid capable of moving vertically and horizontally to provide for engagement between the load site and the designated load capsule. In a grid like matrix, the load capsules may be organized categorically, with a given row dedicated to load capsules carrying algae content, another given row dedicated to load capsules carrying algae medium, etc.
The load capsules may be containers with an opening on one side. The opening may feature a frame configured to lock onto an opposing frame on the load site. The locking engagement may be rotational, snap-fit, or any other feasible way of fixing, temporarily, the opening of the load capsule to the opening of the load site. The sampling site, recycle site, and harvest site, as will be described below, may have a similar engagement mechanism to the track segments.
The material stored in the load capsules may be in liquid form, or powdered/dehydrated form. Conveyance of material into the load sites may occur via gravity or scooping, with the scooping action being manually performed by the user, mechanically facilitated, or mechanically automated. Load capsules may have a scannable code enabling a user to identify the stored material using a scanning device, such as an external controller. The system may also comprise a scanning device disposed adjacent to the load site in order to confirm the identity of the load capsule prior to conveyance.
The track may comprise a series of segments, with each segment sealable via doors, latches, or gates thereby effecting the quarantining of a given segment against other segments. Each segment may feature its own dedicated set of sensors, growth lights, and load sites.
Segments may be designed for modularity, such that additional segments may be added or removed from the track. Modularity components may include various adapters for adapting a segment of a first diameter to a segment of a second diameter. Segments may be joined and sealed together via dedicated joint fixtures and sealing techniques.
Segments may include cultivation tanks, such as photobioreactors. The segments may be made of glass, fiberglass, acrylic, plastic (such as polyethylene, polypropylene, polycarbonate, and PVC), stainless steel, rock/rocksheet, or concrete. Segment diameter and length may be optimized for light penetration and flow control; segment diameter or other flow area measurements may be changed at key points or throughout the system, either dynamically (via the opening and closing of doors, latches, and gates, the replacing of one pipe segment with another, or telescopically) or passively, by designing the system so that key segments in the system have designated measurements for desired flow properties. Segments may be straight, coiled, or serptentine, and vertical, horizontal, or sloped.
The segments may include safety features, such as pressure relief valves, compressors, and pumps for preventing or alleviating high-pressure zones.
The system may comprise a sampling site, which is a system component capable of capturing algae and algae media at one or more positions along the track segments in order to allow closer inspection of algae properties. The mechanism may include a pipetting mechanism configured to be inserted into track segment walls and a pump to convey the sample into the sampling site, or a valve configured to briefly opened for a set duration and then quickly closed, with the valve allowing flow of the sample into the sampling site. The sampling site may enable human operators to manually test the sample, or may provide more finely-tuned sensors to detect sensor data for computer analysis.
The system may comprise a recycle site, which is a system component, typically a vessel and/or a track segment, which is configured to receive, via a flush cycle, described below, or otherwise, algae growth media, such as algae content, unused nutrients, water, etc. The system may comprise a switch for directing the algae growth media from a track segment toward the recycle site. The recycle site may heat, radiate via UV light, chemically treat, or otherwise manage the algae growth media in order to transform the algae growth media into a form appropriate for reintroduction back into the primary track. In one variation, the recycle site is configured to package the recycled algae growth media into load capsules, which are then reintroduced to the primary track.
In addition to recycling the biological material and cultivation medium, the recycling site, or recycling nodes distributed throughout the system, can capture biogas by collection anaerobic digestion of waste. This biogas can be used as fuel for the system. Additionally, heat generated through physical system processes may be captured for targeting heating of the system. Condensation produced by heating water during sterilization or other system processes may be collected and recycled. Further, the system itself may operate to recycle sewage and other wastewater sources as nutrients for the algae. The algae in turn may treat the wastewater, yielding clean(er) water which may then function as its own product of the system.
The system may comprise a harvesting site, which is a system component, typically a vessel and/or a track segment, which is configured to receive, subsequent to a harvesting cycle, algae content for harvesting. The system may further comprise a switch for directing algae growth media from a track segment toward the harvesting site. Harvesting may be designated as “live” harvesting or “dead” harvesting, as will be described.
The harvesting site may convey the harvested algae content into harvest capsules for removal from the system and subsequent distribution. Harvest capsules may include algae growth media, if a live harvest is desired, or else omit the algae growth media if the algae content is desired dead. Accordingly, the harvesting site may be configured to separate the algae content from the algae growth media via dehydration, filtering, and/or straining. Dehydration may occur via an application of heat by the system and/or an exposure to very high-intensity growth lights. Filtering and/or straining may be accomplished via sieves, centrifugation, flocculation, and/or other mechanisms for exploiting variations in density between the algae content and the algae growth media. Flocculants, such as long-chain polymers generally, or environmentally friendly materials such as chitosan may be utilized to facilitate harvesting by binding the particles into aggregates. The harvesting site may include flocculation and/or centrifugation chambers, washing and drying chambers, etc.
In one version, the system comprises a plurality of harvesting sites and a plurality of harvesting site types. One harvesting site type is a live harvesting site, configured to harvest and preserve the life of algae content. Another harvesting site type is a dead harvesting site, configured to harvest by terminating the life of algae content. Harvesting site types may also be distinguished between whether the algae content is desired for use as fuel, food, or beverage.
The system further comprises a set of growth lights. The growth lights may be fixed to a given range of the light spectrum emittance, or may be configured to undergo changes in light spectrum emittance. The growth lights may be controlled by a user through the external controller via the processor.
The controller may feature a start frequency and stop frequency of light spectrum emittance, with the start frequency signifying the lower frequency of the light spectrum emitted by the lights and the stop frequency signifying the higher frequency of the light spectrum emitted by the lights. The stop frequency may be fixed to the start frequency, such that when the start frequency changes, so too does the stop frequency; or vice versa; or the start and stop frequency may be independently modifiable, such that the range of light spectrum emittance may be contracted or expanded by the controller. Light spectrum parameters of the lights may also be set to vary based on time, such that a first start and stop frequency is set for one period of the day and a second start and stop frequency is set for another period of the day. The start and stop frequency may vary automatically based on a set of equations which calculate the frequencies based on feedback from other sensors, the time during a growth cycle, or the time of day.
Additional or alternative light sources may include natural sunlight, starlight, and moonlight.
Temperature control may be provided via conventional temperature systems and mechanisms, such as heaters or coolers. Temperature control may be administered by direct heating of the physical track, including the piping, the infusion into the system of heated (or cooled) fluid flow, such as water or air.
The system may further comprise a turbidity sensor configured to measure the turbidity (i.e., the light scattered by the algae growth media within the liquid portion) of the algae growth medium within given track segments.
The system may further comprise a set of light sensors configured to detect the intensity and type of light emitted within given track segments.
The system may further comprise a set of temperature sensors configured to measure the temperature within given track segments.
The system may further comprise a set of pH sensors configured to measure the pH within given track segments.
The system may further comprise a set of salinity sensors configured to measure the salinity within given track segments.
The system may further comprise a set of oxygen sensors configured to measure the Oxygen level within given track segments.
Sensor data processing may determine whether the algae is dead or alive before instituting a program or protocol. Vibrant colors, such as green, red, or brown, indicate live algae, whereas if limited algae color is detected, the algae is likely dead. Algae spacing and density may also indicate its status, as dead algae tends to clump together and settle down the density gradient. Microscopic examination may reveal whether the cellular structure is intact or shows signs of chloroplast movement (alive) or shriveled or broken (dead). Similarly, fluorometers may detect whether the chlorophyll fluoresce in the presence of light (alive). If the pH is too low, it suggests an over-abundance of carbon dioxide and therefore a lack of consumption of the same (dead). Similarly, a drop in oxygen levels may indicate a lack of photosynthesis (dead). Electrical conductivity patterns of the medium differ in presence of live or dead algae. The rate of nutrient consumption indicates the status as well, with a decrease in consumption indicating that the algae have died.
The controller may be coupled to a user interface, permitting a user to view, research, and mandate one or more parameters, algae status, and system scripts or programs, including one or more cycle types and one or more cultivation types. The user interface may display a set of parameters accompanied by a set of fields, with the user enabled to enter or change the field entry associated with each parameter. The user interface may also enable a user to view all of the load capsules within the load capsule matrix and select one or more for conveyance. The user interface may allow a user to save load capsule groupings in order to make “cocktails” of multiple algae content types, algae medium types, etc.
The system may feature cultivation types, with the cultivation types signifying preferred types of algae cultivation— for example, a first type of cultivation may signify that the algae is intended to be used as fuel, while a second signifies that the algae is intended to be consumed as food, while a third may signify that the algae is intended to be consumed as beverages. Each cultivation type may be associated with a set of default parameters configured to maximize the quality and quantity of the chosen cultivation type. These cultivation types may be selected by a user of the system; after selection, the user interface may display the set of default parameters associated with each cultivation type, such as the intended quantity or mass output of given types of algae, etc., with these associated parameters being customized by the user in order to tweak the desired output.
Cultivation of algae for biomass as fuel may focus in increasing the lipid or carbohydrate content of the algae. Botryococcus braunii, Chlorella, and Nannochloropsis are preferred for their high oil content. The same may be intentionally stressed by the system to further increase their oil content; this stress may be achieved through the reduction of nutrients. Cultivation of algae for food may focus on increasing the nutritional components, such as protein, vitamins, and the elimination of contaminants. Reduction of contaminants are unimportant for algae-as-fuel, but crucial for algae-as-food. Spirulina and Chlorella are preferred for their nutritional value and are considered safe for consumption, and their nutritional output may be increased by reflectively increasing their nutritional intake.
The user interface may feature cycle types, with the cycle types signifying the type of treatment the system will impose on the algae growth media. The cycle types enable the user to control, via the system, the speed of algae cultivation, or else management of the system, such as (live or dead) algae content harvesting, algae content killing, algae growth media flushing, and track sanitization. Some cycle types may include a set of cycles in a sequence. For example, dead algae content harvesting may include the cycles of algae content killing, algae growth media flushing, and finally track sanitization.
The system may feature a harvesting instruction. The harvesting instruction may be split between a “live” harvesting instruction and a “dead” harvesting instruction, with the former designed to keep the algae content alive whereas the latter is designed to terminate algae content life. Harvesting live algae may be relevant for the production of algae-as-food, but for the production of algae-as-fuel, live harvesting is not required. Additionally, the condition of the algae may be determined prior to harvesting— if the algae in an algae-for-food process is determined as alive, live harvesting instructions may be transmitted; otherwise, dead harvesting instructions may be transmitted. Algae for live harvesting may undergo gentle harvesting techniques, such as washing and slow drying in order to preserve cell and nutrient integrity.
The system may feature a kill instruction. The kill instruction is designed to terminate algae cultivation by radically changing one of the system parameters. In one variation, the system may increase the temperature to a level in which algae cannot survive. In another variation, the system may deny introduction of load items or capsules containing a necessary ingredient for algae growth. In yet another variation, the system may increase the growth light intensity beyond algae content life conditions.
In another variation, the system may flush the track by opening waste removal outlets in the track. These waste removal outlets may consist of tangent tracks, with these tangent tracks typically being closed during algae growth cycles. The waste removal tangent tracks may convey flushed algae growth media to the recycle site.
The system may feature a sanitize instruction. Upon selection, the sanitize instruction is designed to clean the track by chemical means, such as with disinfectants like sodium hypochlorite, hydrogen peroxide, quaternary ammonium compounds, or dedicated algaecide cocktails, temperature means, such as hot water, or steam, or with the use of ultraviolet light. In addition, the track segments may be drained for superior surface cleaning. Sanitization instructions may also disengage track segments so that they can be dismantled and cleaned manually and then left to dry to remove any remaining microorganisms. The track segments can also be inspected for rust or other forms of damage before reassembly.
The system is configured to detect, based on sensor feedback, the status of algae content. Particular algae content status facts meriting attention include viability, toxicity, and accordance with cultivation type. Accordance with cultivation type may be detected as lacking if, for example, an incorrect type of algae is being cultivated, as determined by light sensor feedback. As different pH levels are conducive toward the growth of particular algae types, feedback from the pH sensor may indicate whether an undesirable algae content is likely being cultivated. The system may determine whether or not to convey the algae growth media to the recycle site, or the harvesting site based on the aforementioned detection. Further, the system may select whether to transmit the algae growth media to a live or dead harvesting site. Further, the system may select whether the transmit the algae growth media to a food, fuel, or beverage harvesting site.
Each of the recycle site, harvest site, and sampling site may occupy a given portion of track segment or a chamber connected to a track segment with fluid flow engagement.
Typically, the kill, flush, and sanitization instructions are packaged together, such that a single command results in the aforementioned instructions being actuated.
In one variation, the various user interface displays and options may be directed to the system as a whole. In another variation, displays and options may be directed to a given segment. Thus, it may be possible for the user to communicate to the system processor a set of instructions via the external controller, with a first set of instructions for a first segment and a second set of instructions for a second segment.
The system may automatically execute instructions based on detection of various parameters or sensor feedback.
Once a program, script, or cycle is set, the processor may determine whether the conditions of the system, as detected by sensor data, are diverging from preset thresholds native to the program, script, or cycle. Accordingly, the processor may automatically and electronically arrange for the inclusion of additional algae content, nutrients, oxygenation, or any other resource via the load sites or via specialized entryways for the needed resource. The processor may be in instructional communication with the gates and valves to enable the inclusion. The processor may be in instructional communication with the growth lights, heater, and UV light sources, and may control the magnitude, duration, and type, when appropriate, of those resources. Additionally, the processor may be programmed to engage the sampling site for sample capture in order to assist in ensuring that system conditions are as expected or desired.
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This non-provisional application claims priority to and the benefit of provisional application No. 63/479,488, filed Jan. 11, 2023, which is incorporated herein as if restated in full.
| Number | Date | Country | |
|---|---|---|---|
| 63479488 | Jan 2023 | US |
