School of Engineering

CHE 4170 DESIGN PROJECT

Problem Outline And Getting Started
Reference : CHE 4170 2015 Unit Guide

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DESIGN TOPIC 2015

BIOREFINERY APPROACH
FOR BIODIESEL PRODUCTION
VIA ALGAE
A FUTURE TECHNOLOGY
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BIODIESEL PRODUCTION FROM ALGAE

BACKGROUND
SOCIETAL NEED - ENERGY DEMAND

The demand for energy is ever increasing and it is estimated that world would need 197
quadrillion British thermal unit in 2020 [1] from the use of petroleum and other liquid fuels,
which will lead to significant Carbon dioxide emission.

The emission of CO2 contributes to anthropogenic climate change, since these gases
enhance the greenhouse effect in the atmosphere and lead to a warming of the climate
thereby degrading the present and future environment.

On the other hand, the reserves for fossil fuels are depleting and the need for alternative
resources is inevitable.

To overcome these issues, the production and use of renewable biofuels are increasing
(Figure 1) which fulfils the energy demand at the same time mitigating the global warming
potential. One such technology is the use of Microalgae as a source for energy production.

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BIODIESEL PRODUCTION FROM ALGAE

Figure 1 : Global Renewable Biofuel Production ; Source : (2)

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BIODIESEL PRODUCTION FROM ALGAE

FIGURE 1: GLOBAL RENEWABLE BIOFUEL PRODUCTION

Source: [2]

Microalgae are considered to be one of the oldest microorganisms that grow 100 times
faster than terrestrial plants yet utilizing the simple nutrients source and CO2.

The research in finding and evaluating this organism for different commercial purpose
including the production of biofuel is increasing as evident from the scientific publications
(Figure 2). A variety of strains are available for producing lipids which can be converted to
Biodiesel, a non-toxic and greener fuel [3].

However producing Biodiesel alone from microalgae involves multistep process and even
after process system optimization, the projected selling price of biodiesel was US$4.34 per
gallon [4]. Hence there need a process that could target for multiproducts rather than just
focusing on one product.

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BIODIESEL PRODUCTION FROM ALGAE

ADVANTAGES OF USING MICRO-ALGAE DERIVED BIOFUELS

Microalgae are capable of all year round production, hence oil productivity of microalgae cultures exceed the best oilseed
crops.

They grow in aqueous media , but need less water than terrestrial crops , thereby reducing the load on freshwater resources.

Microalgae can be cultivated in brackish water, on non-arable land , and hence may not incur land use change and
associated environmental impacts.

Microalgae have a rapid growth potential and many species have oil content in the range of 20-50 % dry weight of biomass.

With respect to air quality improvements and maintenance , microalgae biomass production can effect biofixation of waste
CO2 (1 Kg of dry algae biomass utilises about 1.83 Kgs of CO2. )

Nutrients from bioalgae cultivation (especially N and P) can be obtained from wastewater, therefore apart from providing
growth medium there is potential for treatment of organic waste from the agri - food industry.

Algae cultivation does not require herbicide or pesticide application

They can produce valuable co-products , such as proteins and residual biomass after oil extraction .

The biochemical composition of the algal biomass can be modulated by varying growth conditions , hence oil yield could be
significantly enhanced.

Microalgae are capable of photobiological production of biohydrogen

Source : Reference 14
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CHALLENGES DEVELOPMENT OF ALGAE BIOFUEL TECHNOLOGY TO COMMERCIAL VIABILITY

Species selection must balance requirements for biofuel production and extraction of
valuable co-products
Attaining higher photosynthetic efficiencies through the continued development of
production systems.
Development of techniques for single species cultivation, evaporation reduction and CO2
diffusion losses.
Potential for negative energy balance after accounting for requirements in water pumping,
CO2 transfer, harvesting and extraction.
Very few commercial plants in operation, therefore lack of data for the sizing of large scale
plants and developing a good understanding of the various techno-commercial and
business viability issues.

Source : Reference 14
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BIODIESEL PRODUCTION FROM ALGAE

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FIGURE 1: GLOBAL RENEWABLE BIOFUEL PRODUCTION (Contd)
Source: [2]

By producing different chemicals such as biodiesel, hydrogen and propylene glycol, the price
of biodiesel could be further reduced to US$2.79 per gallon [5] which is similar to the current
price of diesel.

Even though, the price could be reduced, the incorporation of many chemicals need
separate processing units including reactors and separators which lead to high capital cost.

Alternatively, the price could be reduced by targeting high value products such as proteins,
pigments and omega 3 fatty acids along with the production of biodiesel. This would need
just multiple separation units rather than separate reactor for each product.

At the moment the production of these high value products are commercially available
mostly as a single product production (Table 1). Thus, the aim of this design project is to
identify feasible processing technologies for producing different high and medium value
products along with biodiesel using different strains of microalgae
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Publications of Microalgae
2000.00
1800.00
1600.00
1400.00
1200.00
1000.00
800.00
600.00
400.00
200.00
0.00

Figure 2: Number of publications regarding Microalgae between 1990 and 2014

Source: Scopus

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Table 1 : Major Companies Utilizing Microalgae For Producing High Value Products
COMPANY NAME

SPECIES

PRODUCT

WEBSITE

Haematococcus
for astaxanthin
and Arthrospira
platensis for
spirulina

Natural astaxanthin
(BioAstin) and spirulina
(Spirulina

Seambiotic

Marine
microalgae

Algae-based
nutraceuticals products
and biofuel

Mera Pharma

Haematococcus Natural astaxanthin

(AstaFactor)
Pluvialis

https://www.merapharma.com/about-mera

Fujichemical

Haematococcus Natural astaxanthin

http://www.fujichemical.co.jp/english/life_scie
nce/about_astareal/

Cyanotech

Pluvialis

http://www.cyanotech.com/bioastin/quality.ht ml
http://www.cyanotech.com/spirulina/specificat
ions.html

Pacifica)

(AstaREAL and

http://www.greenprophet.com/2011/09/seabi
otic-biofuel-algae/

AstaTROL)

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CONCEPTUAL DESIGN STUDY SCOPE

The objective of the Conceptual Design Study is to ascertain the technical, social, environmental and
economic viability of a future technology for the production of biodiesel via microalgae biorefinery
approach.

The techno-commercial viability of this project should evaluate the cost as well as feasibility of using
wet and dry microalgae as a feedstock, and the sustainability of different technologies for the
processing of each product including biodiesel by incorporating inherent safety, process system
optimization and project economics, which are considered to be critical for this section.

The site selection will then be evaluated based on the availability of materials such as the need for
marine water or fresh water, utilization of waste products from other companies, and the availability of
the sizeable land for the growth of microalgae or the easier transportation of the microalgae as a
feedstock.

Each group will select the global location for their facility depending on the above criteria. A Life
Cycle Assessment should include the transport and processing of feedstock, but not include
transport or use of the finished product i.e cradle to gate approach. LCA can be restricted only to
Global Warming Potential and resource depletion but need to compare with the base case for
producing the equivalent transport fuel from petroleum.
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PROCESSING OBJECTIVES

A typical petroleum based refinery ranges from 480 to 197000 m3/d (~ 42 to 17174 million gallons per
year (USMGY) while commercial bio-refineries ranges from 3 to 130 (USMGY) [6].

For an Algae based refinery, so far the biggest scale is around 1.5 USMGY which needs 300 acres of
cultivation [7]. A production scale of 175 USMGY was considered in a recent conceptual study [4]. In
this study, production scale of 15 USMGY (330 days) of biodiesel will be considered.

The other valuable products need to be fixed based on the commercial scale production available for
that particular product which will be decided after data gathering. A sensitivity analysis can be
performed by varying the production between 1.5 and 175 USMGY as well.

Different well known species of microalgae will be selected as a feedstock. The data of the
composition of microalgae will be based on the average content of wild species from the scientific
literature and to avoid the bias between the species, no genetic engineering constraint species
should be selected for the evaluation. Figure 3 shows a typical block diagram for algae bio-refinery.

As mentioned earlier, the objective of this project should optimize the maximum high value products
based on the market demand. Processing blocks that are partially excluded from the design scope are
also shown dashed.
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BIODIESEL PRODUCTION FROM ALGAE

Figure 3 A Block Diagram Of A Typical Microalgae Bio-refinery

Biomass

Microalgae
Nutrients

Harvesting

Protein

fermentation
Pigment/
caroteinoid
High value

Lipid

fatty acids

Biog as

Biodiesel

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BIODIESEL PRODUCTION FROM ALGAE

Source : ELSEVIER- Bioresource Technology - Assessment of a dry and a wet route for the
production of biofuels from microalgae: Energy balance analysis, Lixian Xu a,* , Derk W.F. (Wim)
Brilman, a, Jan A.M. Withag b, Gerrit Brem b, Sascha Kersten, a
Monash University Malaysia is jointly owned by Monash University and the Jeffrey Cheah Foundation

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BIODIESEL PRODUCTION FROM ALGAE

Source : ELSEVIER Bioresource Technology - Extraction of oil from microalgae for

biodiesel production: A review, Ronald Halim, Michael K. Danquah, Paul A. Webley
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MAJOR WORK PACKAGES

The design will be based on 15MGY (US) of biodiesel with a plant availability of 330
days per annum.
The design scope is broken into 5 or 6 major work packages for the specification of
equipment items, detailed design, P&ID, and safety assessments.
These are listed in Table 2. Please note that the dashed item in Figure 3 may not be
included in the detailed design depending on the availability of the equipment in other
sections. However, these sections will need to be included for the purposes of mass and
energy balances and/or economics.

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TABLE 2 : MAJOR WORK PACKAGE
Description

Responsibility

Scope

Microalgae Fermentation/Harvesting

ALL

To understand the cultivation

techniques, characteristics and
properties of various grades of
microalgae and to determine the cost
structure and selectivity of feedstock.
Up to Data gathering

Extraction

Person 1

Full design

Pigment/carotenoid

Person 2

Full design

Lipid separation for high value fatty acids

Person 3

Full design

Biodiesel production (Reactor)

Person 4

Full design

Biodiesel separation

Person 5

Full design

Protein/Biogas production

All1

Mass & Energy balances &

PFD and economics by all

Waste treatment and

storage2

Person 6

Full design by person 6

Full design

1Depending

on the complexity of other sections and availability of the product this section will be arranged to
Person 6. This will be decided after the data gathering section.
2Waste treatment and storage facility is applicable to only 6 person team.
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ECONOMIC ANALYSIS

Product And Feedstock

Each design group will estimate a suitable market demand and price for by-products they
produce (done during Data gathering) while fixing the price of biodiesel to US$ 2.79/gallon
as a base case to evaluate the feasibility between producing value added chemicals and
producing high/medium value products.

It is expected that based on the different high and medium value products, the cost of
producing biodiesel will vary. The sensitivity analysis could include the variation of
biodiesel price. Feedstock prices will be determined by each group individually.

Other Operating Costs

Utilities are available as listed in Table A4, at the costs provided. Labour will be at the rate
appropriate to the location. Royalties and selling expenses should also be estimated

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CAPITAL COST

The capital cost estimate will include the inside battery limits (IBL) plant, and a reasonable allowance for
other elements of the outside battery limits plant, which will include: feedstock storage (if any) and storage
of products at least 2 weeks of production, utility water and steam supply, air supply, waste water
treatment, a laboratory, maintenance and an administration buildings.

While estimating the cost, the capital cost of producing with and without the high/medium value products
will be considered.

The design life of the equipment, piping etc will be 25 years. The economic life will be assumed to be 20
years of operation.

If the outcome of this study is positive and recommends that the project be sanctioned, then it can be
assumed, that a further year is required for detailed design and procurement and an additional two years is
required for construction and commissioning. The economic objective is to determine the lowest possible
price of biodiesel.

A real discount rate (zero inflation) of 10% is to be used for the cost of capital. However the project IRR will
dictate the eventual outcome.

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TABLE A1 : FEEDSTOCK AND ITS COMPOSITION*
Typical
Options Of
Fermentors

Water
Source

Lipid
Content

Protein
Content

Carbohydrates
Content

High Value Fatty

Acids

Pigments

34%

6%

Eicosapentaenoic
Acid (20 : 5w3)

Fucoxanthinchl
orophyll

21%

48%

17%

Alpha-linolenic
acid (C18 : 3w3)

Zeaxanthin

[1316]

Freshwater

63%

28%

11%

Pentadecanoic
(C15 : 3)

Canthaxanthin

[8, 14,
17-19]

Flat plate

Freshwater

23%

36%

41%

Pentadecanoic
(C15 : 3)

Carotenoid

[8, 14,
17,
18,
20]

Chlorella
sorokiniana

Inclined tubular

Freshwater

22%

42%

32%

Pentadecanoic
(C15 : 3)

Chlorophyll a

[8, 14,
17,
18,
21]

Chlorella vulgaris

Open ponds, basins,

glass-tube,

Freshwater

40%

7%

55%

Pentadecanoic
(C15 : 3)

-carotene

[8, 17,
18,
22]

Marine

18%

35%

7.8%

Palmitoleate (C16
: 1w7)

Violaxanthin
and

[8, 9,
14,
23]

Group

Feedstock

Chaetoceros
calcitrans

Tubular

Marine

16%

Chlamydomonas
reinhardtii

Flat plate

Freshwater

Chlorella emersonii

Flat plate

Chlorella
protothecoides

PBR
7

Nannochioropsis
oculata

Flat plate

chlorophyll a

Ref

[8-12]

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TABLE A1 : FEEDSTOCK AND ITS COMPOSITION* (Contd)
Typical

Protein
Content

Group

Feedstock

Options Of
Fermentors

Water
Source

Carbohydrates
Content

High Value Fatty

Acids

Pavlova salina

Photobioreactor

Marine

12%

26%

7.4%

Scenedesmus
obliquus

Continuous
stirredtank

Freshwater

12-14%

50-56%

10-17%

10

Synechococcus sp.

Biosolar

Marine

11%

63%

11

Tetraselmis suecica

Column

Marine

10%

12

Arthrospira

Tubular
photobioreactor

Freshwater

13

Dunaliella salina

Tubular loop

Marine

14

Botrycoccus Braunii

Pigments

Ref

Eicosapentaenoic
acid (C20 : 5w3)

[8, 9,
24,
25]

Myristoleic (C14
: 1)

Neoxanthin and

[8, 13,
18,
26,
27]

15%

Hexadecanoic
acid (C16 : 0)

Chlorophyll a

[13, 2830]

31%

12%

Oleic acid (18

: 1w-9c)

Chlorophyll a

[8, 9,
14,
31,
32]

6-7%

60-71%

13-16%

Hexadecanoic
acid (C16 : 0)

Phycocyanin

[13,
14,
33,
34]

6%

57%

32%

Linolelaidic (C18
: 2n6t)

Carotenoid

[13,
18,
35,
36]

Lipid
Content

chlorophyll a

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Table A2 Biodiesel Blendstock (B100) Specification For U.S. And European [37]
Property

Water and sediment (vol.%, max)

Biodiesel blendstock (B100)

U.S. (ASTM D6751-08)
Limits
Method
0.05
D 2709

Total contamination (mg/kg, max.)

Kinematic viscosity @ 40 C (mm2/s)

Europe (EN 14214)

Limits
0.05

Method
EN 12937g

24

EN 12662

1.9-6.0

D 445

3.5-5.0

EN 3104/3105

93

D 93

101

EN 3679

0.20a
47
Reportd

EN 14110
D 613
D 2500

0.20
51
Country Specificd

EN 14110
EN 5165

0.020

D 874

0.020

EN 3987

5.0

EN 14538

5.0

Gp II Metals Ca + Mg (mg/kg, max.)

5.0

EN 14538

5.0

EN 14538

Total Sulfur (ppm, max.)

Phosphorous (ppm, max.)
Acid no. (mg KOH/g, max.)
Carbon residue (wt.%, max)

15b
10
0.50
0.05

D 5453
D 4951
D 664
D 4530

10
4
0.50
0.30e

EN 20846
EN 14107
EN 14104
EN 10370

Flash point, closed cup (C, min)

Methanol (wt.%, max.)
Cetane no. (min)
Cloud point (C)
Sulfated ash (wt.%, max.)
Total ash (wt.%, max.)
Gp I metals Na +K (mg/kg, max.)

EN 14108/14109

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Table A2 Biodiesel Blendstock (B100) Specification For U.S. And European [37] (Contd)
Property

Free glycerin (wt.%, max.)

Total glycerin (wt.%, max.)

Biodiesel blendstock (B100)

U.S. (ASTM D6751-08)
Europe (EN 14214)
Limits
Method
Limits
Method
0.02
D 6584
0.02
EN 14105/14106
0.25

EN 14105

Mono glyceride (wt.%, max)

0.80

EN 14105

Diglyceride (wt.%, max)

0.20

EN 14105

0.20

EN 14105

No. 1

EN 2160

6.0
12.0
1.0

EN 14112
EN 14103
prEN 15799

96.5

EN 14103

120
860-900

EN 14111
EN 3675

Triglyceride (wt.%, max)

Distillation (T90 C, max.)
Copper strip corrosion (3-h at 50 C,
max.)
Oxidation Stability (h @ 110 C, min)
Linolenic acid methyl ester (wt.%, max)
Polyunsaturated acid methyl esters
(wt.%, max)
Ester Content (wt.%, min)
Iodine Value (g l2/100 g, max.)
Density (kg/m3)
Lubricity @ 60 C, WSD, microns
(max.)
Cold Soak Filterability (seconds, max.)

0.24

36c

D 6584

No. 3

D 1160
D 130

3.0

EN 14112

360f

D 7501

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NOTES TO SPECIFICATION TABLE

a : Alternatively, flash point must be >130 C

b : For blending with USLD. For other fuels, hifgher sulphur levels are allowed

c : Atmospheric equivalent T-90 point

d: Low temperature properties are not strictly specified, but should be agreed upon by the
fuel supplier or purchaser.

e : This limit is based on the bottom 10 % fraction of the fuel, not the entire fuel.

f : 200 seconds for use in diesel blends at low temperature (, -12 C)

g : Method EN 12937 measures total water (in units of micro g/g), but not sediment

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Table A3 : CO2 And Biomass Productivity For CO2 Mitigation Species
Microalgae

T()

CO2 (%)

P (Volume)
(g l-1 day-1)

P (CO2)
(g l-1 day-1)

Carbon

Ref.

utilisation
efficiency
(%)

Chlorella sp.
Chlorella sp.
Chlorella sp.
Chlorella sp.
Chlorella sp.
Chlorella kessleri
Chlorella vilgaris
Chlorella vulgaris
Chlorella vulgaris
Chlorella vulgaris
Scenedesmus sp.
Scenedesmus sp.
Scenedesmus obliquus
Scenedesmus obliquus
Scenedesmus obliquus

26
26
26
26
26
30
25
25
25
27
25
25
30

0.682a

Air
2
5
10
15
18
10
Air
Air
15
10
Flue gas
Air
Air
18

1.445a
0.899a
0.106a
0.099a
0.087
0.105
0.040
0.024
0.218
0.203
0.009
0.016
0.140
a

0.624
0.016
0.031
0.260

58
27
20
16
-

[38]
[38]
[38]
[38]
[38]
[39]
[40]
[41]
[41]
[42]
[40]
[40]
[43]
[43]
[44]

Culture incubated for 4-8 days.

26

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UTILITIES
Electricity: 22KV / 415V / 3 Phase/50 Hz
Natural gas: LHV 34.6 MJ/m3 Mains Pressure 10 Bar (g)

COST OF SUPPLY / TREATMENT

RM 0.35 /kWh
RM 21.80/MM Btu

Towns Water

State/Country Specific

Cooling water

Towns Water + RM 0.30/M3

Treated Water

Towns Water + RM 0.90/M3

Oxygen: Liquefied Gas 10 Bar (g)

RM 1.00/M3

Nitrogen : Liquefied Gas 10 Bar (g)

RM 0.80/M3

Saturated steam (10bar (g))

RM 80/Tonne

Hot water @ 90C

Sea water
Industrial grade water
Carbon dioxide Liquefied Gas

RM 1.20/kg

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www.myettnews.com/.../07/biodiesel-algae.JPG
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2. Photo Bio Reactor Systems

A Photo-Bioreactor in Translucent
Tube from GreenFuels

Global Green Solutions/Vertigro Vertical Photo

Bioreactor System

http://www.braziltexas.org/attachments/contentmanagers/1/1Thurmond_PDF_Presentation.pdf

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http://algaefuel.org/products-PBR-photo-bioreactor-biodiesel-making-system-green-energy.html
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2.
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8.
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Silva, C., et al., Commercial-scale biodiesel production from algae. Industrial and Engineering Chemistry Research, 2014. 53(13):
p. 5311-5324.
Gong, J. and You, F., Value-added chemicals from microalgae: Greener, more economical, or both? ACS Sustainable Chemistry
and Engineering, 2015. 3(1): p. 82-96.
Association, R.F. http://www.ethanolrfa.org/bio-refinery-locations/. 2015 [cited 2015 14 June].
Columbus. http://www.columbusnewmexicobiorefinery.com/. 2012 [cited 2015 14 June].
Singh, J. and Gu, S., Commercialization potential of microalgae for biofuels production.Renewable and Sustainable Energy
Reviews, 2010. 14(9): p. 2596-2610.
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