Algae Production Systems focuses on the manufacture, sales and support of equipment for the production of Algae, Algae Oil and Algae Biomass Algae production is a growth industry with significant potential. As early as 2008, there were more than 300 commercial biodiesel plants in operation with a combined production capacity of over 1.2 billion gallons of biodiesel, along with hundreds of commercial-scale distributors selling the fuel throughout the United States, including Hawaii and Alaska. Today there are over 1100 commercial fueling stations providing algae based biodiesel fuel. Biodiesel has become the only alternative fuel to have fully completed the health effects testing requirements of the 1990 Clean Air Act Amendments. Quality standards have been developed and it has been legally registered with the Environmental Protection Agency as a legal motor fuel for sale and distribution.
Algae Oil and Biomass
Algae Oil is the result of the process of growing the algae microorganism to sufficient mass that it can be harvested and processed through a system where the walls of the single cell organism are caused to burst, releasing the hydrocarbon liquid (Lipid) contained within the cell. This oil is collected and processed to reduce the percentage of water in the oil to the point that it is usable as a vegetable oil feedstock in the transesterification process whereby biodiesel fuel is manufactured. Another use for algae, which is proving to be even more profitable than the production of biodiesel fuel, is the use of the algae biomass as ORGANIC fertilizer. It is environmentally friendly, safe for human consumption and produces higher crop yields.
THE APS PROCESS DESCRIPTION
- Algae Production Systems has selected a specific methodology to be applied to each of the three steps in the process of producing algae oil, which are 1) grow algae 2) harvest the algae and 3) extract the Oil and biomass. The manner and order in which our process functions is, in some cases, a unique departure from the way in which algae has been grown, harvested and oil extracted in laboratory environments. Our design for the photo bioreactor, while not radical, is unique in the way that it addresses various factors that maximize the growing process, while minimizing labor requirements. Labor-intensive systems quickly drive up the cost of production. Our system design minimizes human intervention and maximizes computer control of the various processes. Our systems are designed to be “continuous” process rather than “batch” process, which further minimizes labor requirements and helps to maximize production rates. We minimize the loss of aquatic medium through the use of a closed photo bioreactor system.
- Algae Production Systems uses a closed photo bioreactor system. Unlike other “full Flood” photo bioreactors our system functions much like a raceway pond that has been constructed above ground using clear materials with a cover. Raceway ponds are proven technology, but our photo bioreactor has many advantages over open systems, such as being protected by the cover from unwanted organisms/bugs and from contamination by rogue algae strains. This methodology also allows for the control of various other elements effecting the rate of growth of the algae, such as temperature, flow rate, maximized sun light application, CO2 concentration, nutrient level maintenance, UV filtering and Oxygen removal. The photo bioreactor is designed as a single pass system from inoculation to harvest. Any un-matured algae and aquatic medium recovered from the harvesting and extraction processes, will be returned to the inoculation tanks, thereby returning a maximum amount of aquatic medium to the growing stage. This also provides operational economies through the conservation and return of nutrients to the system.
- The extraction process is a two-step process involving the pressing of the algae to burst the cell walls, releasing the oil and separating the solids (biomass) from the liquids (oil and water) and then separating the oil and water. Pressing is accomplished using commercially available press equipment. Centrifuges will be used for the separation of the algae oil from the water. Water recovered from this stage will not contain live algae, however any water suitable for reintroduction into the system will be processed for return to the inoculation tanks.
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