Algoliner - Bio Reactors

Since the production of these profiles will be carried out at the very location the PBRs are installed, no joints between pipe elements are required. This is not just saving material and production effort but also allows using profiles other than simply round tubes. Consequently, it was possible to realize a hanging system which additionally provides an improved stiffness compared to standard (round) profile types. As a consequence, the amount of required raw materials as well as manpower to build these PBRs is substantially lower compared to all other common methods to realize horizontal pipe type PBR`s.

The chosen materials and the fixing concept of our profiles are engineered for a life time of more than 20 years.

The concept would also allow the realization of multi-channel profiles to combine either cooling, illuminating or CO₂ distribution during the operation.

Algoliner was established in 2013 as a start-up to realize the above mentioned concept which is also subject to worldwide patents. As a European company we expect to find potential partners in the US to introduce and further promote our concept.

Since the profiles are being produced endless at the PBR location, no joints are required and consequently the profiles can have also other shapes to integrate more functions.

Realized profile

• Concept with an inner diameter of 50 mm.
• Integration of LED light chain would be possible.

Potential profiles

• The cooling water can be coloured to influence the cooling or the radiation
• Shading elements can be added into the cooling fluid to achieve a flickering effect onto the growing channel.
• The outer surface of the channel can be modified to influence the radiation.
• If requested the profiles can be hang with the help of tray bars.

How do we solve the thermal expansion of the profile?

Since the Algoliner profiles are hanging, the profiles are flexible and they can move to the side to compensate the thermal expansion. Various tests have been done already to validate this concept.

Results of our tests:

The thermal expansion coefficient of PMMA is about 70x10^-6 [1/K]

The real thermal expansion of plastic parts is usually lower than the calculated because a part of the expansion is being covered from the elasticity of the part.

In our test we found the real expansion to be maximum 50% of the theoretical. This effect is because our profiles are very flexible and a large portion of the expansion is covered from an elastically deformation.

Conclusion:

With the right compromise between the hanging concept, type of profiles, distance between the posts and maximum temperature, the thermal expansion can be compensate by allowing the profile to deform elastically.

Words from the inventor of the Algoliner concept

As we speak, 7,4 billion fellow humans share this our planet with us. Most respectable surveys suggest that our planet will have to cope with a population of 10 billion and higher during the course of this century. Meanwhile, an estimated 170 million people reach the middle class annually according to an OECD study. Naturally, the need for energy, food and consumption in general is rising substantially in the developing world. Meanwhile, the so called "developed world" has not done enough to slow down let alone reduce their hunger for energy. It is thus obvious that we face an enormous challenge: Meet needs for continued population growth and ever rising standards of living all while not creating an ecologic overburden to our planet.

Relatively soon after the most tragic 2011 nuclear disaster in Fukushima, Japan, the German government decided to eventually abandon the production of nuclear energy for good. The outbreaking debate regarding the feasibility of this without question eager plan made me look back onto my own life. As a young man, I have partly financed my studies with building rotor wings for wind energy systems. Frankly, despite greatly enjoying this work, I was not convinced that wind energy would ever play a serious role in any states energy production. However, time would prove me and many others wrong. Considering that the state of Germany already creates some 13 percent of it`s entire produced energy from wind energy; in hindsight I should have probably stayed in that industry. While this decision lies behind me, it nevertheless demonstrates what is really possible. We simply cannot continue todays unsustainable resource depletion, just to emit even more CO₂ into the atmosphere.

As a father of two sons, this wish to leave a planet worth living to future generations has been with me ever since. Eventually, while thinking about usable solutions to the mentioned problems I learned about the astonishing potential of micro algae. Micro algae produce more biomass per surface than any other plant on the planet. High quality substances for the food, feed, chemistry and energy sectors are to be won out of this plants biomass. All this, while mainly using CO₂ and sunlight –both being very abundant– for production. Moreover, in case of closed cycle systems the required amount of water is rather low. What a phenomenal possibility, to create biomass while taking CO₂ out of the atmosphere.

What a nice dream!

Unfortunately, so far the success of micro algae has remained far behind its true potential. In my opinion excessive water evaporation of open pond photobioreactors (PBRs) seriously limits the applicability of those. Much more useful are closed PBR systems, in that they only use a friction of the amount of water needed for open pond PBRs. However, to date, those closed PBR systems could not be realized and operated on truly competitive price levels. Algoliner provides an innovative solution to substantially reduce those costs.

Just a dream?

During a 30 year career in the automotive industry, I have reached a comprehensive expertise in various mass production technologies. As an university graduate for plastics engineering and a state graduate for business/economy, my main motivation has always been to improve quality while reducing costs. A dream will always remain a dream, if cost for the realisation cannot withstand market pressures. What separates a truly revolutionary idea from a mere dream is it`s "real life" applicability. It is thus that I set myself ambitious targets as to the "real life" applicability of my idea.

The following Statement of Requirements (SOR) lists indispensable targets we have set for our product. It should be/have:

• Substantially cheaper than any conventional PBR ($ per volume).
• An operational lifetime of at least 20 years even in harsh conditions.
• Small ecological footprint (environmentally friendly and recyclable materials).
• Low energy consumption for set up and operation (mostly solar).

Closed system PBR`s exist in various varieties. Most commonly the pipes that are foreseen to hold the algae are assembled either vertically or horizontally. So far, manufacturers would produce those required pipes and cut those into pieces for transportation only to be reassembled at the site of the future PBR. I will not have to convince you that this practice lacks any logic. The amount of time and materials spent to reconnect those pipes are enormous, and the final pipe will hardly reach the stability it had in it`s original condition.

Algoliner provides a simple, logic and much more cost effective alternative. I have designed a mobile factory, that allows for pipe production at any required place. It has taken us a considerable amount of effort to combine all features a static factory provides into a mobile one. However, having added features as heating, cooling, air-pressure, ventilation, vacuum and more into our mobile unit we are well equipped, and allow me to say: It is working just fantastic! Mainly because with Algoliner there is no need to connect single pipe parts, the entire PBR is being set up by one single worker. With the help of numerous remote controlled winches, our up to 100 meter (>300`) long pipes may be lifted into position with the literal flick of a finger.

For mainly reasons of easy processing, extrusion experts love materials like PVC or PE. For me however it has been a non negotiable condition to use Plexiglas (PMMA) from the beginning on. While this material is indeed tricky to process, it provides for outstanding qualities in the final product. It`s superior transparency, scratch- and sunlight resistance make it the ideal raw material for PBRs. Yet, there was one problem: None of the plastic processors we contacted offered great assistance, as this material is so difficult to handle. Nevertheless, we followed through with this plan anyway, and the results are more than satisfying. On top of the above mentioned PMMA qualities, we have managed to produce pipes with a thinner wall thickness than any other supplier on the market.

As you may have seen on this website, our pipe profiles are not purely round. Because we do not have to reconnect our profiles, we are not bound to strictly round profiles. This allowed us to modify the shape of our profiles so we can hang those. Why hang profiles? The answer is as simple as it is genius: It significantly reduces the profiles required wall thickness, as well as the amount of holding racks. It hence saves more than half of the amount in raw materials, and thus dramatically reduces cost. Imagine the difference between hanging profiles and standing profiles by thinking of bridges. Imagine profiles to be the bridge`s deck, while the bridge`s pillars were to symbolize holding racks. Compared to ancient bridges, modern hanging bridges –as San Francisco`s Golden Gate Bridge for instance– require less pillars and and a thinner deck to cover tremendous distances. In addition, the overall structure is able to withstand considerable movement of the profiles (deck), without obtaining any damage. In our opinion, hanging profiles are the much more logic solution compared to common concepts.

Due to my 30 years experience in mass production, we have made sure that all elements such as holding devices, end pipes, feeding elements or sensors have been designed so they could be produced using the most cost efficient mass production technologies.

All the above mentioned concepts are subject to already granted or currently pending patents. We are excited for future tasks, and look for worldwide partners to bring in their specific know how. All this with the overarching goal to realize the most cost efficient production method for the production of biomass with micro algae.

How much is a dream worth, if in fact it will never be realizable? Algoliner`s unmet cost efficiency will let this dream become reality. A vision of biomass production that will help contributing to higher living standards for a growing world population. All while not producing, but in fact reducing CO₂.