US20140065687A1 - Bioreactor System and Related Bio-Stimulation Methods - Google Patents

Abstract

A bioreactor system for growing commercial volumes of algae or other biomass in an enclosed, biosecure reactor vessel, the system having internal artificial growth light production as well as exterior solar energy capturing devices or the like designed to facilitate enhanced sunlight exposure for photosynthesis organism production. Magnetic and electromagnetic field generation systems and/or millimeter wave generating devices are integrated with the bioreactor system and its operation to substantially enhance growth rate and overall productivity.

Description

CROSS-REFERENCE TO RELATED APPLICATION
• This application claims the benefit of U.S. patent application Ser. No. 12/772,970, filed on May 3, 2010, which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/175,256, filed May 4, 2009, both of which the contents are incorporated by reference herein.
FIELD OF THE INVENTION
• The present invention relates to the field of bioreactor systems, and, more particularly, to a production system utilizing biostimulation devices for growth of algae and other biomass.
BACKGROUND OF THE INVENTION
• Algae is recognized as a valuable resource, with proper cultivation and processing providing many products, including fuels, feed, and a diverse array of chemicals which have uses in pharmaceuticals and nutritional products such as Omega-3 oils.
• The production of algae has sustainability advantages when compared to traditional land based crops and fossil fuels. Significant carbon savings are achieved by using energy-rich algae as a feedstock and source of biofuel, since algae consumes more harmful CO₂gas than is generated when its products are used as fuel or within other chemical products.
• Algae has the potential to provide cost effective, economically sustainable substitution for existing fuels and feeds, which have been traditionally produced from fresh water intensive, agriculture land-based crops such as corn and soybeans, and from fossil petroleum.
• Algal biomass is also known to provide high-protein concentrate (or higher-purity isolate) suitable for animal use or fish feed, and can be made suitable for human consumption. There is an established market for these algae type protein supplements amongst consumers.
• It is also known that algae may contain over 50% oil by weight, depending upon the species; other species may contain cellulose or sugar, both of which can be synthesized into fuels, in the amount of up to about 40% by weight. Furthermore, after processing, the remaining 60% to 70% of biomass can be used for valuable non-fuel applications, including, but not limited to, specialty chemicals, nutritional supplements, pharmaceuticals, feeds, food, naturally derived pigments, personal care products.
SUMMARY OF THE INVENTION
• In view of the foregoing, it is an object of the present invention to provide a cost-effective and controlled bioreactor system for small and large scale production of energy-rich algae or other forms of biological biomass utilizing magnetic fields to stimulate microbial growth and metabolism.
• In accordance with one aspect of the present invention, the bioreactor system comprises a containment vessel having a wall with inner and outer sides forming an interior having an inner diameter, lower and upper ends, and a medial area therebetween. Furthermore, a generally vertically oriented flow tube is positioned in the interior of the containment vessel such that the flow tube forms a longitudinal passage having a bottom, a top, and a medial area therebetween. The containment vessel and the flow tube are collectively structured to facilitate the circulation of fluid biomass between the interior of the containment vessel and the longitudinal passage of the flow tube.
• The flow tube may also have one or more medial flow passages in the vicinity of the medial, and other areas, of the longitudinal passage laterally formed therethrough. A gate valve is configured to slideably engage the wall of the flow tube so as to selectively block flow through the medial flow passage when the interior of the containment vessel is filled to a predetermined fluid level.
• The wall of the containment vessel may have ports formed therethrough, each of the ports covered via a port cover formed of fluid impermeable, light transmissive material for transmission of light energy into the containment vessel for stimulation of cellular mitosis. Furthermore, at least one of the ports may also include an artificial light source mounted so as to project light into the interior of the containment vessel.
• In some embodiments, the inner diameter of the interior of the containment vessel at the lower and upper ends is less than the inner diameter of the containment vessel at the medial area, such that longitudinal flow of matter between the inner walls of the containment vessel and the flow tube encounter an increase in turbulence.
• In some embodiments, the containment vessel of the system includes at least one conduit containing a first conduit portion and a second conduit portion in fluid communication with the containment vessel to form a closed loop, and the conduit further includes magnetic coils concentrically mounted thereon in a spaced fashion along a length of the conduit to selectively provide a tunable millitesla magnetic field within the conduit for the purposes of creating bio-stimulation (increasing cellular mitosis and growth rate).
• In some embodiments, the flow tube of the system has a lower stop attached and positioned below the medial flow passage to support the sliding gate valve in a position such that fluid passes through the medial flow passage of the flow tube. The flow tube may also have attached thereto an upper stop positioned above the medial flow passages to stop upward migration of the sliding gate valve and position the sliding gate valve to block the medial flow passage formed in the flow tube, so as to substantially prevent the passage of fluid therethrough. The flow tube may also have a lower airlift therein positioned below the medial area of the flow tube, the lower airlift formed to provide a pressure gradient to provide fluid lift in the flow tube. Likewise, an upper airlift may be positioned in the flow tube above the medial area of the flow tube, the upper airlift formed to provide a pressure gradient so as to provide fluid lift in the flow tube. The flow tube may also include a carbon dioxide (and/or other useful gas) infusion array in communication for infusing carbon dioxide and other useful gas forms, such as nitrogen, into the flow tube.
• The system may further comprise magnetic coils concentrically mounted to the flow tube, the magnetic coils mounted in spaced fashion along a length of the flow tube to selectively provide a tunable electromagnetic field within and about the flow tube (for bio-stimulation of the fluidized organism growth cycle (growth and mitosis) or, alternatively, for cellular disruption for oil collection). Such a configuration may include a Helmholtz coil, or the like.
• The containment vessel may include a top portion disposed at the upper end, the top portion being transparent to light and defining a headspace above the top of the flow tube, whereby fluid biomass flowing from the top of the flow tube is exposed to light for stimulation of cellular growth and mitosis and photosynthesis.
• In some embodiments, the upper end of the containment vessel includes a microwave or other type of millimeter wave emitting device disposed at such end and configured to project millimeter waves into the containment vessel such that flow from the top of the flow tube is exposed to the millimeter waves for increasing cellular growth rate and mitosis or, alternatively, for cellular disruption.
• In some embodiments, the bioreactor system includes at least one auxiliary vessel, such as a flat panel enclosure, in fluid communication with the containment vessel, the auxiliary vessel having first and second panels mounted in a spaced fashion to define an enclosure therebetween. At least one of the first and second panels is formed of a light permeable material. Furthermore, the enclosure is configured to receive a flow of fluid biomass from the containment vessel, and the auxiliary vessel is configured to facilitate the passage of the flow of fluid biomass through the enclosure so as to receive light energy radiating therein for stimulation of mitosis and growth rates and photosynthesis. The enclosure may also include one or more diffusers and/or one or more pumps in communication therewith for facilitating the flow of the fluid biomass from the enclosure to the containment vessel. For maximum energy balance, the fluid flow system is designed to be empowered by the hydrostatic pressure generated by the fluids in the containment vessel feeding the base of the lower auxiliary vessel enclosure and returning back to the top of the containment vessel via a fluid air lift pump located at the top of the auxiliary vessel. Furthermore, an artificial light source may be disposed to project light through at least one of the first and second panels into the auxiliary vessel, so as to radiate and reflect light energy for stimulating organism photosynthesis within the biomass fluids migrating inside and through the enclosure.
• Furthermore, in some embodiments, at least one linkage tube is in fluid communication with the containment vessel and the auxiliary vessel of the system. The at least one linkage tube includes first and second, or more, magnetic rings concentrically mounted thereon such that the first and second, or more, magnetic rings are in a spaced fashion along a length of the first tube to selectively provide a tunable magnetic field within the linkage tube. The linkage tube may also include, or alternatively include, a solenoid coil device concentrically mounted thereon to selectively provide a tunable bio-stimulation magnetic field within the linkage tube that is controllable by electrical current.
• In accordance with another aspect of the present invention, a flat panel bioreactor system having a top side and underside is described. The system includes first and second panels configured in a spaced fashion onto a frame so as to define at least one enclosure therein, the enclosure having first and second ends, the first panel defining the top side, the second panel defining the underside; a first tube (preferably perforated) configured with apertures along its length to disperse fluid biomass into the enclosure at its base, the first tube disposed along and generally parallel to the first end of the enclosure; a second tube configured with apertures along its length to disperse air, CO₂and other useful gasses into the enclosure, the second tube disposed proximal to the first tube; wherein the enclosure is configured to facilitate the flow of fluid biomass within the enclosure so as to receive light energy radiating therein. The one or more enclosures are each configured to facilitate the flow of fluid biomass within the enclosures and have pressurized air/CO₂injected into the enclosure to mix the biomass within the enclosures so that the growing microorganism can receive maximum natural and artificial light energy radiation and cellular respiration therein.
• According to a method aspect of the invention, a method of cultivating one or more organisms in a biomass comprises the steps of filling a bioreactor with a starter culture of a biomass suspended in a fluid. The bioreactor comprises a containment vessel having a wall having inner and outer sides forming an interior having an inner diameter, lower and upper ends, and a medial area therebetween; a generally vertically oriented flow tube positioned in said interior of said containment vessel, said flow tube forming a longitudinal passage having a bottom, a top, and a medial area therebetween; said flow tube having laterally formed therethrough, in the vicinity of said medial area of said longitudinal passage, one or more medial flow passages; a gate valve configured to slideably engage said wall of said flow tube so as to selectively block flow through said medial flow passage upon said interior of said containment vessel being filled to a predetermined fluid level; wherein the starter culture is filled to about the medial flow passage.
• The method further includes effectuating flow of gas in the flow tube at least below the medial flow passage, so as to provide an upward flow such that the upward flow facilitates the flow of fluid through the medial flow passage, out of the upper region of the flow tube, down the exterior of the flow tube, and back into the bottom of the flow tube in a looped fashion; monitoring the biomass for growth; and filling the bioreactor to about the top of the flow tube, causing movement of the gate valve into a position so as to block the medial flow passage and urge the flow through the top of the flow tube, down the exterior of the flow tube, and back in through the bottom of the flow tube in a looped fashion.
• In some embodiments of this aspect of the invention, the method further includes one or more of the following steps: effectuating a flow of gas in the flow tube above the medial flow passage, so as to provide upward flow; exposing the interior of the containment vessel to one or more types of magnetic (or electromagnetic) fields, so as to stimulate cellular mitosis in the biomass flowing therethrough; exposing the interior of the containment vessel to millimeter waves to stimulate cellular mitosis (i.e., bio-stimulation) in the biomass flowing therethrough; creating an acidic type cellular disruption condition in the containment vessel so as to weaken the cellular body of the biomass; exposing the interior of the containment vessel to one or more pulsed magnetic fields, so as to break the cellular wall of the biomass to separate lipid oil content therein from the cellular body of the biomass; and/or exposing the biomass to millimeter waves tuned so as to provide a pulsed field at a frequency and field strength to break the cellular wall of the biomass to separate lipid oil content therein from the cellular body of the biomass.
• These and other objects, features and advantages of the present invention will become clearer when the drawings as well as the detailed description are taken into consideration.
BRIEF DESCRIPTION OF THE DRAWINGS
• For a fuller understanding of the nature of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:
• FIG. 1A is a side, exterior view of a bioreactor system according to an embodiment of the present invention;
• FIG. 1B is a side, exterior view of a bioreactor system according to an embodiment of the present invention, illustrating an acrylic structure disposed in the medial section of the containment vessel;
• FIG. 2A is a top, cutaway view of a port of an embodiment of the present invention.
• FIG. 2B is a front view of a solar grow light array according to an embodiment of the present invention.
• FIG. 2C is a top, cutaway view of the solar grow light LED array ofFIG. 2B as placed in the port ofFIG. 2A.
• FIG. 3 is a side, cross-sectional view of a flow tube according to an embodiment of the present invention.
• FIG. 4 is a side, cutaway view of a bioreactor system according to an embodiment of the present invention.
• FIG. 5 is a top, perspective view of the inside of the flow tube of an embodiment of the present invention, illustrating an upper airlift, a gate valve, a lower airlift, and a carbon dioxide infusion array therein.
• FIG. 6 is a side, partial cutaway view of the bioreactor system ofFIG. 4 illustrating the system as partially filled with fluid, with a gate valve in a lower, open configuration, with circulation occurring through medial flow passages formed through the flow tube, and the operation of a lower airlift and the carbon dioxide infusion array.
• FIG. 7 is a side, partial cutaway view of the bioreactor system ofFIG. 4 illustrating the system as filled with fluid, with the gate valve in an upper, closed configuration to prevent flow through the medial flow passages formed in the flow tube, with circulation occurring through the top of the flow tube, and the operation of the upper and lower airlifts and carbon dioxide infusion array.
• FIG. 8 is a top, cross-sectional view of a flow tube according to an embodiment of the present invention.
• FIG. 9 is a side, exterior view of a bioreactor system according to an embodiment of the present invention utilizing a millimeter wave emitter therein.
• FIG. 10 is a side, cross-sectional view of the bioreactor system ofFIG. 9.
• FIG. 11 illustrates a top, cross-sectional view of the bioreactor system ofFIG. 9.
• FIG. 12 illustrates a side, cross-sectional view of a bioreactor system of an embodiment of the present invention including an auxiliary vessel structured as a flat panel enclosure.
• FIG. 13 is a front, partially cutaway view of the flat panel enclosure ofFIG. 12.
• FIG. 14 is a side, detailed view of the flat panel enclosure ofFIG. 12.
• FIG. 15A is a side, detailed view of the flat panel enclosure ofFIG. 12, illustrating a functional orientation thereof.
• FIG. 15B is a side, detailed view of the flat panel enclosure ofFIG. 12, illustrating a functional orientation thereof.
• FIG. 16 is a side, partial cross-sectional view of the flat panel enclosure ofFIG. 12.
• FIG. 17 is a side, partial cut-away view of the flat panel enclosure ofFIG. 12.
• FIG. 18 is a side, partial cut-away view of the flat panel enclosure ofFIG. 12.
• FIG. 19 is a side, partial view of the flat panel enclosure ofFIG. 12.
• FIG. 20 is a side, exterior view of a bioreactor system according to an embodiment of the present invention utilizing a millitesla tunable energy rare earth magnet structure for bio-stimulation of cell growth thereon.
• FIG. 20A is a perspective view of the tunable energy rare earth magnet structure illustrated inFIG. 20.
• FIG. 21 is a side, exterior view of a bioreactor system according to an embodiment of the present invention utilizing millitesla tunable energy electric powered solenoid magnet for bio-stimulation of cell growth thereon.
• FIG. 22 is a side, exterior view of a bioreactor system according to an embodiment of the present invention, configured as an array.
• FIG. 23 is a top view of the bioreactor system array ofFIG. 22.
• FIG. 24 is a project flow diagram of an exemplary embodiment of the present invention.
• FIG. 24A is a flow diagram providing detail on reference letter “A” inFIG. 24.
• FIG. 24B is a flow diagram providing detail on reference letter “B” inFIG. 24.
• FIG. 24C is a flow diagram providing detail on reference letter “C” inFIG. 24.
• Like reference numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION
• Reference is made to particular features (including method steps) of the invention. It is to be understood that the disclosure of the invention in this specification includes all possible combinations of such particular features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment of the invention, that feature can also be used, to the extent possible, in combination with and/or in the context of other particular aspects and embodiments of the invention, and in the invention generally.
• The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the indefinite articles “a”, “an” and “the” should be understood to include plural reference unless the context clearly indicates otherwise.
• The phrase “and/or,” as used herein, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases.
• As used herein, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating a listing of items, “and/or” or “or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number of items, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e., “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.”
• The term “comprises” is used herein to mean that other elements, steps, etc. are optionally present. When reference is made herein to a method comprising two or more defined steps, the steps can be carried out in any order, or simultaneously (except where the context excludes that possibility), and the method can include one or more steps which are carried out before any of the defined steps, between two of the defined steps, or after all of the defined steps (except where the context excludes that possibility).
• As used herein, the terms “including”, “includes”, “having”, “has”, “with”, or variants thereof, are intended to be inclusive similar to the term “comprising.”
• In this section, the present invention will be described more fully with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will convey the scope of the invention to those skilled in the art.
• As illustrated in the accompanying drawings, the present invention is directed to a bioreactor system and related methods. Such bioreactor systems may be utilized for growth of biomass, such as algal growth, and/or utilized in renewable energy and valuable chemical production processes.
• Referring initially toFIG. 1A, the bioreactor system1000 comprises acore bioreactor1 including acontainment vessel2 having abase3 and first4 and second4′ stacked tank sections. The tank sections are generally connected via a flange orlip5 with a gasket or other form of sealant to form a structure with lower6 and upper6′ ends with amedial section7 therebetween. The corebioreactor containment vessel2 is generally shaped in a cylindrical form with an inner diameter; however, themedial section7 may have a larger diameter than the upper6′ and lower6 ends to promote turbulence in the flow of fluids along its inner wall during operation.
• The first4 and second4′ tank sections forming the corebioreactor containment vessel2 may be formed of a variety of durable materials, such as but not limited to, fiberglass, acrylic, stainless steel, plastics, and the like. As shown inFIG. 1B, the first4 and second4′ tank sections may alternatively engage anacrylic structure7′, or other clear material, forming themedial section7 therebetween to provide for additional light penetration into thecontainment vessel2. Furthermore, foam may be embedded between multiple layers of material forming thecontainment vessel2 to provide insulating properties. For example, a layer of polystyrene foam may be imbedded between an inner and outer skin forming thetank sections4,4′. The first4 and second4′ tank sections may contain honeycomb tubular heating and cooling radiators within the layers of polystyrene foam insulation to circulate heated or cooled liquid to maintain a desired bioreactor and biomass fluid temperature in order to maintain a proper organism cultivation temperature.
• Theupper end6′ of thecontainment vessel2 forms an opening which is enclosed via atop portion8 which defines a headspace at the top of thecontainment vessel2. Thetop portion8 may be transparent to light so as to allow natural solar light transmission into the top of thecontainment vessel2 and/or for observation. Thetop portion8 may alternatively be non-transparent if the biomass to be cultured or grown does not require additional solar energy. In some embodiments, thetop portion8 is shaped as a dome to provide for space for attachment of additional components, such as growth bio-stimulation devices (e.g., millimeter wave devices), for stimulating the biomass as it flows underneath.
• Continuing withFIG. 1A and further referring toFIGS. 2A,2B, and2C, theside walls9,9′ forming the first4 and second4′ tank sections, respectively, may optionally have formed therethroughopenings10,10′ (inFIG. 1A under thecovers18 shown) for the placement of clear or opaque material, such as acrylic. The clear or opaque material may be shaped into adome11 structure projecting into the corebioreactor containment vessel2 in a concave disposition. Theopenings10,10′ and clear/opaque material may be structured to house an artificial light source attached to theinside wall16,16′ of the tank sections, such as light bulbs or LED lights, or let natural solar transmission therethrough.
• For artificial light, an array ofLED lights14, designed to emit focused, high intensity artificial grow-light energy15 for photosynthesis into the interior of the corebioreactor containment vessel2, may be placed in the concave space formed in the dome so as to utilize thedome11 as anenclosure12 for receiving alight source13.
• Thelight source13 in the embodiment illustrated inFIG. 2C is mounted to acover18 which also acts as a heat sink for the heat generated by the LED lights which is engaged to theouter tank wall16,16′ via fasteners or the like to provide access for light maintenance and inspection, while protecting thelight source13 from weather elements. Gaskets or other sealing materials are provided between thedome11 and tank wall to prevent fluid penetration into theenclosure12. In the present exemplary embodiment, gasket material is used to seal the top and sides of the edges of the light mounting device which engages the tank wall, with the lower non-gasketed portion left open to the outside of the tank for air circulation.
• Observation panels63,63′ may be provided on the first4 and second4′ tank sections forming the corebioreactor containment vessel2 to allow operators to view the interior during operation or maintenance, or the like. Also, the first4 or second4′ tank sections has formed therein a man-way entry opening with a fluid tight entrance panel built into the side to permit access to the interior and sized for allowing personnel to enter the unit for maintenance, cleaning, repair, and otherwise as required.
• The LED light systems utilized may have energy equivalents of metal-halide artificial solar lights in the proper wavelengths to stimulate growth of biomass, such as algae. The LED lights may be air-cooled by small electric fans that circulate outside air through anair inlet19 formed along the bottom edge of the LED light mounting covers.
• Turning toFIGS. 3,4, and5, theflow tube22 for placement within the core bioreactor containment vessel2 (not shown) is illustrated. Theflow tube22 has alongitudinal passage37 therethrough, alength20, and an inner/outer diameter21′ configured within thecontainment vessel2. Theflow tube22 may be fabricated of various materials, such as but not limited to PVC or fiberglass materials, having a flow tube loweropen end23 and flow tube upperopen end23′, with amedial portion24 therebetween, and passages/apertures39,39′ formed laterally through themedial portion24 in spaced fashion about thediameter21′ offlow tube22.
• The flow tube loweropen end23 may havesidewall17lower flow cutouts26,26′ forming legs to support theflow tube22 vertically on thebase3 of the corebioreactor containment vessel2, thecut outs26,26′ also providing an opening for the flow of fluid from the corebioreactor containment vessel2 into the flow tube loweropen end23 for recirculation. The vertically situatedflow tube22 may be centered within the interior41 of the corebioreactor containment vessel2.
• As shown, within theflow tube22 near the flow tube loweropen end23, but abovecutouts26,26′, is acoil43 of perforated air hose forming alower airlift28, the coil is aligned with and mounted to theinner diameter21 of flow tube in loops from a header system fed by an air supply line for maintaining a continuous, slow movement of the biomass growth medium within the maturation chamber of thecore bioreactor1.
• Referring toFIG. 5, configured in thebase3 of the corebioreactor containment vessel3 is a growth medium (bloater) returnport54′ (for return of material into thecore bioreactor1 after monitoring/processing or for selectively draining the system). One ormore air diffusers30,30′,30″,30′″ may be disposed in theflow tube22 and usually spaced above thelower airlift tube28 connected to one another via acircular hose44 to form a CO₂(carbon dioxide), or other gas,infusion array29, each of the diffusers situated generally equally spaced from one another to form an upwardly facing ring of diffusers, the outer periphery of which is adjacent to theinner diameter21 of theflow tube22. The diffusion of CO₂or other gases into the base of theflow tube22 helps control pH, for example; this gas delivery system can also be used to infuse other forms of gas treatments, such as compressed air and/or nitrogen for nutrients.
• Spaced above the CO₂infusion array29, in themedial portion24 of theflow tube22 is a gate valve31 (which is preferably a floating gate valve) comprising aring body32 having first46 and second46′ ends defining alength47, anouter diameter48 and inner48′ diameters. Thering body32 is formed of acylindrical surface49, theouter diameter48 of which is slightly less than theinner diameter21 of theflow tube22 so that thering body32 may slidingly engage theinner diameter21 of same.
• Thering body32 is preferably formed of a material which has a positive buoyancy in water or other fluid in use, and is formed to rest upon lower stops50 (seeFIG. 4) affixed to the inner diameter of theflow tube22, with stops positioned to support the first, lower end of the ring body, when the system is not operational or when liquid in the system is about half way up the corebioreactor containment vessel2.
• The cylindrical surface of thering body32 has formed therethroughflow apertures51,51′ situated to be aligned withmedial flow passages39,39′ formed medially in theflow tube22 when thering body32 is resting onlower stops50,50′ to provide medial flow through theflow tube22, whileupper stops52,52′ are provided in spaced fashion above the lower stops50,50′ so as to position thering body32 to close the flow through themedial flow passages39,39′ when thering body32 is in its floating, upper position.
• Referring again toFIG. 4, situated within theinterior diameter21′ of theflow tube22, preferably just above themedial portion24 of the tube, is theupper airlift40, formed of aring43′ or coil of perforated air hose in general alignment with and adjacent to the inner diameter of theflow tube22, and configured to disperse air into the upper inner diameter of theflow tube22 during operations at full fluid level.
• Generally, the upper andlower airlifts40,28 are similar in construction and uniquely spaced apart so that an air blower, or other device, providing the air thereto can overcome the head pressure of the liquid or other fluid within thecore bioreactor1, whether half full (using only the lower airlift28) or completely full (using one or both of the airlifts), thus minimizing energy expenditures for operation.
• Energy efficiency is an important consideration as to the commercial viability of enclosed bioreactor systems, and the present airlift design greatly adds to the efficiency of the present system by allowing for circulation of the biomass without the necessity of utilizing accessory pumps, as well as providing a major operating cost advantage.
• In some embodiments, situated proximal to the flow tube upperopen end23′ of theflow tube22 is an electromagnetic coil device, preferably in the form of a Helmholtz coil, comprising first53 and second53′ electromagnetic coils spaced54 or otherwise situated a distance from one another, to selectively provide an electromagnetic field. Thecoils53,53′ form concentric rings on the outside of theflow tube22. Alternatively, as illustrated inFIG. 10, first53″ and second53′″ electromagnetic coils are spaced, or otherwise situated, a distance from one another on the inside of theflow tube22, forming concentric rings. The electromagnetic fields stimulate microbial growth and metabolism of the biomass.
• In some embodiments, the interior wall of theflow tube22 forming theinner diameter21 is of a dark or other light absorbing color to provide a dark interior, and/or the outer wall forming theouter diameter21′ of flow tube has a light reflective coating, such as a mirror or metallic color coating, the reflective finish formed to reflect and scatter the natural and artificial solar energy emitted through the top portion of the upper end of the corebioreactor containment vessel2 andtransparent domes11,11′,11″ with optional LED grow light arrays mounted therein (seeFIGS. 2B and 2C) within the interior41 of thecontainment vessel2 of the bioreactor system. Further, the reflective finish can be applied to the inside of thetop portion8 where it is impractical or undesirable to have natural sunlight pass through thetop portion8. By providing reflective material on the outer wall of theflow tube22 and the inner wall of the core bioreactor containment vessel, an enhanced reflective light chamber is formed in the annular area between the outer walls of theflow tube22 and theinner walls16 of the corebioreactor containment vessel2.
• To further enhance the reflection of the inner walls of the core bioreactor containment vessel2 (and thetop portion8 if a reflective finish is desired) glass beads may be used to create a multi-directional, highly reflective and saltwater durable coating upon the underlying reflective finish.
• The dual reflectivity of the outer flow tube, on one side, and the inner walls of the corebioreactor containment vessel2, on the other, combined with the high intensity LED light arrays projected therein, and the turbulent flow of an photoautoropic organism therethrough provides an enhanced light exposure chamber which, when utilizing a UV filteredtop portion8 for natural light exposure coupled with the artificial light: a) takes advantage of improved sidelighting, b) increases the surface area illuminated, c) drastically reduces photosynthetic saturation, d) demonstrates the ability to achieve much higher volumetric carbon fixation rates, e) filters unwanted UV and IR radiation from the bioreactor, f) minimizes heat delivery, and e) increases the overall sunlight utilization efficiency and cost-effectiveness.
• Referring toFIG. 1 andFIGS. 3-6, in the first stage of operation of the bioreactor system for growing algae or the like, a growth medium solution with the algae and added water forming aliquid suspension57 is provided with the start upfluid level55 filling about one half of the core bioreactor containment vessel2 (the “start up” stage) so that thegate valve31 is not lifted by the liquid (or in the lower orientation if by separate mechanical means), and remains at its lower stage resting uponlower stops50,50′, the water level being about even with themedial flow passages39,39′ formed through the sidewalls of theflow tube22.
• Filtered air (possibly UV sterilized as well) can be urged from a blower via a hose to thelower airlift28 so that air bubbles56 emanate therefrom to form in the surroundingliquid suspension57, urging the liquid suspension within theflow tube22 to flow58 upward as the air bubbles rise, with the liquid suspension flowing in61 through thelower flow cutouts26,26′, when theupward flow58 reaches the start upwater level55, where the bubbles are released into the air above thewater level55.
• The flow at thewater level55 then passes59 through the gatevalve flow apertures51,51′ and the alignedflow tube22medial flow passages39,39′, where it flows downward60, encounteringdomes11,11′, which create turbulence within the system to allow a mixing effect of the algae in suspension to become exposed to the grow-light energy57, while preventing settling of the algae suspended therein. Microscopic plant-like organisms require only milliseconds of exposure to specific grow-light wavelengths for cell division to occur which will be provided by the reflective exterior of the flow tube bouncing the high intensity LED light energy back and forth from the reflective finish of the interior reactor wall thus creating a light chamber to maximize grow-light exposure to the algae as they circulate through the illuminated chamber.
• The flow through thegate valve31 andmedial flow passages39,39′ through theflow tube22 is necessary for startup to provide liquid suspension/bloater circulation over the LED solar grow lights indomes11,11′ in the lower half of the bioreactor corebioreactor containment vessel2, since algae organisms require concentration of cell count during organism maturation, and prior to dilution into larger growing volumes.
• As a result, typically the entire bioreactor system cannot be fully loaded withliquid suspension57 during the initial organism growth start-up period. Therefore, only the lower half of the bioreactor is used to allow sufficient time to concentrate the algae population before adding additional liquid and nutrients to raise the fluid level to the top of the bioreactor, where either natural solar light and/or other forms of electromagnetic/magnetic energy for inducing bio-stimulation of growth rate are provided for photosynthesis at the top of the corebioreactor containment vessel2.
• During operation, theliquid suspension57 can be monitored for algae concentration, purity, pH, CO₂level, oxygen nitrogen and other algae nutrient levels, salinity (where salt water species are cultivated), as well as other factors. The PH is adjusted via the use of a pH monitoring/probe and an optional control device that controls an electric valve that automatically allows the injection of CO₂gas into the system by an external air control and filtration system which sterilizes and mixes ambient air and blows the mixed gasses into thediffusers30,30′,30″,30″ and/or through the lower28 and upper40 airlifts. Pure CO2 and other mixed gases may also be controlled and injected via the micro-diffusion disks located in the bottom of the flow tube. Any of the air/CO₂delivery systems can add CO₂to the system for 24/7 automatic PH control. PH may also be adjusted via known chemical additives. Liquid nitrate and other forms of liquid fertilizer & nutrients may be automatically added if the system is in a algae production mode. A nitrate/nutrient formula for organism growth is added into the bioreactor via the use of a nitrate monitoring/sensor probe and computer control device that reads the upper and lower ranges of nitrates in solution within the liquid biomass in the bioreactor and regulates (opens & closes) an electric fluid valve and correspondingly turns on & off an electric fluid pump that automatically provides organisms with controlled injections of liquid nitrate fertilizer balanced with a pre-mixture with other organism growth vitamins and minerals and injected into the bioreactor system from external liquid fertilizer storage tanks via a flow line that feeds into the bottom/center of the main bioreactor where it is mixed into the biomass liquid by the air lift system.
• Equipment can be utilized, such as a FlowCam™ Monitoring device, for 24/7 detection of the system's positive or negative change in algae biomass concentration, and a nitrate sensor/controller so the bioreactor systems can be manually or computer controlled via on-site or remote controlled management systems. Once sufficient growth is confirmed, the fluid level with nutrients and other additives may be raised tofull fluid level64 along with full bioreactor system operating status, as illustrated inFIG. 7.
• Still referring toFIGS. 1-7, once the water level rises above the midpoint fluid level55 denoted inFIG. 6, thering body32 forming the gate valve is lifted65 by its buoyancy in the rising liquid, lifting thering body32 from its resting position onlower stops50,50′, floating upwards until thering body32 is stopped from further rising viaupper stops52,52′. At the upper stops52,52′, thering body32 is positioned so that thespace66 in the ring body between theflow apertures51,51′ and lower,first end46 of the ring body blocks themedial flow passages39,39′, blocking the flow of fluid/biomass therethrough, allowing the fluid in theflow tube22 to flow through67 thering body32.
• Once the fluid level rises above theupper airlift40, air flow is initiated through thering43′ or coil of perforated air hose forming same, replacing the air flow from thelower airlift28 as earlier discussed, theupper airlift40 airflow further dispersing air bubbles56′ into the upper inner diameter of theflow tube22 to further enhance theair lift68 action and enhance upward fluid circulation within and out of the flow tube upperopen end23′ of theflow tube22.
• After passing through theupper airlift40, the liquid suspension passes through the previously discussed first53 and second53′ electromagnetic coils forming the Helmholtz coil (in embodiments of the bioreactor system containing the Helmholtz coil).
• During growth operations at full tank level (as shown inFIG. 7), the Helmholtz coils are energized to produce a homogeneousmagnetic field69 approximately aligned with the centrallongitudinal axis70 of the bioreactor system flow tube, and extending outward to at least the inner walls of the bioreactor corebioreactor containment vessel2, which may have electromagnetic shielding in place to prevent the field from extending out of the bioreactor system. In alternative embodiments, the Helmholtz coils may be positioned inside of theflow tube22. Likewise, the coils can be positioned above the airlift hoses located in the upper and lower sections of theflow tube22. The size of the coil can vary to generate different magnetic field strengths, dependent on the biomass to be stimulated.
• A uniform, low frequency magnetic field that charges the water molecules with energy, which, at low energy levels, transfers into stimulating cellular growth, may be utilized. Furthermore, higher energy levels may be utilized when desirable to cause cell lysis (splitting the cell wall) for oil/cellulose separation operations.
• For use in improving the cellular growth rate of the biomass, the electromagnetic field strength generated by the Helmholtz coil device is expected to operate between 15 and 100 Hz at 2 ut, 4 ut, 6 ut, 8 ut and up to 100 ut.
• Once the air lifted biomass has flowed through the Helmholtz coils located near the top of thedarkened flow tube22, it may be exposed tonatural sunlight71 from the transparenttop portion8 of the bioreactor system, and/or artificial growing lights. The biomass may also receive microwave millimeter wave energy, non-ionizing radiation for bio-stimulation (stimulation of growth rates) when required projecting from thetop portion8 into the corebioreactor containment vessel2.
• The biomass then flows over the flow tube upperopen end23′ and encounters downward flow72 due to siphoning action due to flow61 through thelower flow cutouts26,26′ inflow tube22, caused by the lifting action from the upper40 air lift within theflow tube22.
• As mentioned above, during this period of flow downward from the flow tube upperopen end23′ to the flow tube loweropen end23, the biomass is exposed to artificial grow light from the LED's situated in the ports along the length of thebioreactor containment vessel2, while light is reflected off the outer reflective surface of the flow tube, providing an enhanced grow light chamber with turbulence generated by the uneven inner surface of the corebioreactor containment vessel2 due to themany domes11 housing the LED sources13.
• In addition, the shape of thebioreactor containment vessel2, with a widermedial section7 relative to the lower6 and upper6′ ends, causes further turbulence within the reactor as created by the air-lift system as it pushes out of the flow tube22 (either medially or out of the top, depending upon the water level).
• The biomass continues to be drawn downward along the interior wall of the corebioreactor containment vessel2 and exterior theflow tube22 as it continues to be exposed to the enhanced grow LED lights, until the suspension reaches the bottom of thebioreactor containment vessel2, where it is drawn through61 thelower flow cutouts26 of theflow tube22, and into and up the dark interior of the lower flow tube, wherein the biomass (e.g., algae) “rest” (in the dark) as it travels up the length of the interior of theflow tube22, (where it may be again exposed to an EMF field via the Helmholtz coil and/or microwave millimeter wave energy device (if utilized and desired), ultimately flowing out of the top of theflow tube22, from dark to light, where the biomass is again drawn down the exterior of the tube and exposed to the artificial and/or natural sunlight, as the cycle repeats.
• Referring now toFIGS. 9,10 and11, in addition to or in place of the Helmholtz coil system previously described herein, embodiments of the present invention may include a tunablemillimeter wave generator74 with a concomitant wave guide transponder/antenna73 associated with the top center of the top portion disposed at the upper end of the corebioreactor containment vessel2, to provide within the bioreactor system a controlled tuneable millimeter waveelectromagnetic radiation75, which is beamed to thefluid surface level81, where it penetrates the surface to generate the bio-stimulation of cell division (mitosis) by enhancing the regeneration cycle of the biomass (e.g., algae). Examples of known millimeter wave emitters which may be suitable for this purpose may include traveling wave tubes including a backward wave tube also known as a backward wave oscillator (BWO) or carcinotron and other millimeter wave sources including other vacuum tubes. Additional millimeter wave sources/emitters would be understood by those skilled in the art and are contemplated to be utilized in the present invention.
• The millimeterwave emitting antenna73 is positioned in the center vicinity of the top portion (e.g., acrylic dome) of the corebioreactor containment vessel2 and configured to emit a special frequency EMF millimeter wave (preferably 10 mW/cm²and less) with exposure times that may vary from about 20 minutes per day to 24 hours per day, dependent upon the cell-division rate and the type of organism being grown. Generally, low-intensity millimeter waves, generally 10 mW/cm²or less, cause an increase in growth and proliferation of various organisms, as described by Pakhomov et al. in “Current state and implications of research on biological effects of millimeter waves: A review of literature,” (found at http://www.rife.org/otherresearch/millimeterwaves.html) and incorporated herein by reference in its entirety.
• To contain the EMF wave within thebioreactor containment vessel2, a layer of EMF wave reflection and shieldingmaterial76 may be laminated to the inside surface of the top portion, as well as an upper portion of the upper, second4′ section forming the corebioreactor containment vessel2. Preferably, the EMF shielding andreflection material76 associated with thetop portion8 of the corebioreactor containment vessel2 is formed of material that allows the passage of natural or artificial light energy associated with photosynthesis therethrough.
• The unique configuration of this embodiment of the bioreactor system design is such that the biomass (e.g., algae) and growth medium exiting79 the second upperopen end23′ of thebioreactor flow tube22 is briefly situated at theupper water level81, and as such is briefly exposed to the millimeter waveelectromagnetic radiation75.
• It is noted that, althoughFIG. 11 illustrates the operation of a Helmholtz coilelectromagnetic field69 and amillimeter wave field75, this is not to indicate that both theelectromagnetic field69 and themillimeter wave field75 are provided simultaneously, and either may be provided individually without the other operating, as may be desirable.
• During operation of the system, the cell division rate may be monitored via a cell counting device, such as, for example, the FLOWCAM™ imaging system previously discussed herein and/or the Hach nitrate monitor and controller, and the data utilized to operate, either manually or via computer control, the millimeter wave and/or Helmholtz EMF generator and other electromagnetic biostimulation devices further described herein located in thecore bioreactor1 and/or auxiliary vessel80 (e.g., flat panel enclosure) and/or the pH/CO₂injection and nitrate fertilization controller to optimize cellular development of the cultured organisms.
• It is noted that the present bioreactor system may also be used in a non-photobioreactor capacity to provide enhanced growth of non-photosynthetic organisms, such as but not limited to yeast cultures, (for food, alcohol and drug production, for example), bacteria cultures, and other microorganisms or the like; and the use of the artificial and solar lighting capacities my not be required, depending upon the microorganism being cultured.
• In some embodiments, once the cell count is determined to reach the optimal level for harvesting, the Helmholtz device and/or the millimeter wave device, or an exterior microwave device can be used, to expose the cells (e.g., algae) to an appropriate frequency and dose of electromagnetic energy for separation of the biomass into the component lipids and polysaccharide (cellulose) fractions.
• In such an operation where separation into component lipids and polysaccharides is desirable, an infusion of CO₂gas is injected into either the liquid medium via the CO₂infusion array (29 inFIG. 4) or mixed with an ambient air generator system to add CO₂within theflow tube22 situated in the corebioreactor containment vessel2 in order to effect a drop in the pH (acidic condition) in the liquid medium, so as to weaken the algal cell body. A microwave, millimeter wave, and/or EMF (electro-magnetic field) source generator or the Helmholtz coils53,53′, are tuned to provide a pulsed energy field at a precise frequency and field strength, as would be understood by those skilled in the art, in order to facilitate the fracturization of the cellular wall, to allow for the separation of the cellular lipids/oils from the cell detritus remaining after fracturing.
• In this case, cell density may be monitored, the appropriate microwave or other frequency for optimal cell lysis is selected, and the cell contents (lipids and polysaccharide/protein components) are separated.
• This initial separation process may be conducted within the bioreactor system or may be completed in a separate electromagnetic device set-up to function in conjunction with an exterior separation and settling tank. The device is expected to use electromagnetic field strength generated by a separate EMF generator of sufficient frequency and power output to effect the lysis of the cell walls of the algae.
• Referring again toFIGS. 1A and 1B, in some embodiments the core bioreactor may include at least onebio-stimulation conduit77,77′ in fluid communication therewith. Thebio-stimulation conduit77,77′ includes afirst conduit portion77 and asecond conduit portion77′, the first andsecond conduit portions77,77′ in fluid communication with the corebioreactor containment vessel2 to form a closed loop. The bio-stimulation conduit further includes first and second (or more)magnetic rings25,25′ concentrically mounted thereon. The magnetic rings are slideably mounted in spaced fashion along a length of the bio-stimulation conduit to selectively provide a tunable magnetic field within the bio-stimulation conduit for providing magnetic field energy in the 5 to 200 millitesla range to the biomass circulating within the bio-stimulation conduit at various flow rates to magnetically bio-stimulate the growth rate of the micro organisms flowing through the conduit. The magnetic field is selectively tuned by creating rear earth magnets of various selected magnetic strength and by sliding the first and second (or more) magnetic rings at varying distances from each other and/or in “repulsing” or “attracting” orientations. An energy efficiency benefit of the magnetic rings is that they are made of rare earth magnets and, therefore, do not require electricity to provide the magnetic field.
• Referring again toFIG. 4, in some embodiments, the bio-stimulation conduit includes asolenoid coil103 wrapped around one or both of thefirst conduit portion77 and asecond conduit portion77′ such that, at various flow rates, and selected electromagnetic fields of millitesla energy may be applied to the organisms flowing through the conduit. Thesolenoid coil103 provides a magnetic field within the bio-stimulation conduit that is controlled by a tunable direct current (DC) or other forms of electrical current. As such, the magnetic field is tunable and can be fine tuned to provide a desirable wavelength for bio-stimulation of cellular growth of the particular organism that is being cultured/grown in the bioreactor system1000. Likewise, thesolenoid coil103 may be utilized for determination of a proper wavelength by adjusting the current over time to determine the ideal wavelength. Once the ideal wavelength is determined, thesolenoid coil103 may be kept at such a setting, or the solenoid coil is replaced with multiple magnetic rings that are tuned to the magnetic wavelength previously determined by the tuning of the electric solenoid coil.
• Referring now toFIGS. 12-14,15A,B, and16-19, to supplement the core bioreactor, at least oneauxiliary vessel80, preferably as a flat panel enclosure, is provided, to provide enhanced natural, as well as artificial, sunlight exposure (for night or as otherwise required) for the growth of organic biomass. Theauxiliary vessel80 is exterior to thecore bioreactor1 of the system1000. Theauxiliary vessel80 is generally formed of flat panels; however, such panels could be of a curvilinear form providing curvature to theauxiliary vessel80.
• Theauxiliary vessel80 further accelerates photosynthesis (in systems where photosynthesis is required of the biomass being grown) by means of increasing the amount of photon exposure to the growth medium by flowing the fluid biomass throughrectilinear enclosures84,84′ exposed to natural and/or artificial sunlight. The auxiliary vessel can also filter unwanted UV and IR radiation from the biomass and minimize heat delivery. Theauxiliary vessel80 in the form of a flat panel enclosure of the illustrated embodiment is formed of arectilinear frame85 having amedial divider85′ to form a barrier therebetween, dividing the frame into first86 and second86′ cells, each cell having alength93, awidth93′, and adepth94. Thefirst cell86 is formed to engage afront panel82 andrear panel83, while thesecond cell86′ engages and supports a separatefront panel82′ and arear panel83′, the front82,82′ panels being opposed to and equally spaced from the rear83,83′ panels, respectively on each flat panel enclosure unit. Thepanels82,82′,83,83′ are preferably formed of material transparent to the wavelengths of light conducive for photosynthesis to the biomass. The sheets are formed of glass, thefront panels82,82′ spaced101 from therear panels83,83′ to form first84 and second84′ enclosures therebetween, associated with the first86 and second86′ cells, respectively; however, as it would be understood by those skilled in the art, acrylic or other rigid, transparent materials may be utilized in place of glass.
• The front82,82′ and rear83,83′ panels may have applied thereto a layer of inwardly92 facing, so called, one-waymirror window film93,93′ (such as manufactured by 3M of St. Paul, Minn. or the like) so as to allow the passage of light therethrough95 for photosynthesis into eachrespective enclosure84,84′, but reflect95′ any light seeking to pass out of the enclosure, in order to provide an enhanced light chamber for any photosynthetic culture (including algae or the like) situated therein or passing therethrough. A film laminate or the like to the panels may also be used to reduce harmful UV light, while allowing the passage of optimal wavelengths of light for photosynthesis therethrough.
• The rear83,83′ panels may have mounted to the frame outside of theenclosures84,84′, projecting into said rear83,83′ panels with LED growlight arrays116,116′ and 117, 117′, to provide a source of artificial grow light from the rear of the bioreactor into the enclosures where the biomass flows, providing enhanced grow light capabilities even at night, indoors, or on cloudy days. The control of the artificial grow light system is either manually or automatically controlled via a light sensing device that regulates the length of each grow light period.
• Also mounted exterior the rear83,83′ panels of the first86 and second86 cells are optional fluorescent tube growlights123,123′,123″ and 124, 124′,124″, respectively, to provide further artificial photosynthesis lighting through the rear83,83′ panels and into their respective enclosures. The metal enclosure surface area located behind the florescent and LED grow lights is mirror finished to reflect the natural and artificial grow light energy being radiated either from natural sunlight from outside of the flat panel enclosure or from the artificial grow-lights from behind the rear glass of the flat panel enclosure.
• In some embodiments, various sizes of bio balls are utilized inside of theauxiliary vessel80 and core bioreactor that are neutrally buoyant and circulate within the inside of the vessels with the water/biomass. The spiny bio balls rub against the inside of the vessels' walls and help to keep the surface areas from accumulation of algae or bio-organism film on the inside surfaces. This “filming” that occurs with algae and other organisms will retard or cloud out the amount of natural and artificial sunlight entering the vessels.
• Theauxiliary vessel80 is generally situated on asupport frame87 having a base89 with first90 and second90′ ends. The first90 end is formed to receive andsupport91 the first end88 of theauxiliary vessel80. The base89 may have emanating therefrom avertical support96, which can be used to support (via chains, for example) theauxiliary vessel80 such that thefront panels82,82′ face the sun. A hingedsupport beam91 having first97 and second97′ ends is also provided. Thefirst end97 pivotally engages98 thebase89, and thesecond end97 engages thepanel frame87 to support theauxiliary vessel80 in theproper angle99 to receivemaximum sun exposure100 depending upon the latitude and the time of year.
• In operation, the fluid or growth medium borne biomass will gravity flow (enhanced via hydrostatic head pressure in thebioreactor containment vessel2 and/or assisted with an air lift pump or electric powered fluid pump) from the bottom to split103 via at least onelinkage tube106 or the like to flow to the bottom orfirst end102,102′ of the first84 and second84′ enclosures forming theauxiliary vessel80 where the fluid borne biomass flows out110 (or is pumped) of aperforated line109,109′, so that the water borne biomass flows along the width of each of the first84 and second84′ enclosures. As would be understood by those skilled in the art, thelinkage tube106 would not necessarily require asplit103 if theauxiliary vessel80 consists of a single enclosure; likewise, thelinkage tube106 could split multiple times when a plurality of enclosures form theauxiliary vessel80.
• Referring toFIG. 20, the at least onelinkage tube106 may further include multiplemagnetic rings25″,25′″ concentrically mounted thereon, to form a tunable energy rare earth magnet structure, the magnetic rings mounted in spaced fashion along a length of the linkage tube to selectively provide a tunable magnetic field for bio-stimulation growth enhancement within the linkage tube (as previously described herein). The tunable energy rare earth magnet structure is shown in more detail inFIG. 20A. The magnet structure could be utilized in various configurations in concert with thecore bioreactor1 and/orauxiliary vessel80 where a conduit or linkage tube is structured to provide flow of the biomass. Furthermore, the magnet structure illustrated inFIG. 20A could also be used in any system where biostimulation of a biomass is desirable.
• As shown inFIG. 21, the at least onelinkage tube106 can also (or alternatively) include a solenoid coil concentrically mounted (positioned) thereon to selectively provide a tunable magnetic field for bio-stimulation growth enhancement within the linkage tube (as previously described herein).
• In the exemplary embodiment of the present invention, it is noted that the hydrostatic head pressure of the fluid within the core reactor (bioreactor containment vessel2) will fill theauxiliary vessel80 without a pump, when thebottom level120 of theauxiliary vessel80 is lower than thehigher fluid level122 within thecontainment vessel2 of the core reactor.
• Theperforated line109,109′ in the exemplary embodiment comprises a pipe with holes on top and both sides spaced apart along a length of the pipe. In addition, adiffuser hose114 is aligned with and situated adjacent to theperforated line109 and provides sterilized/filtered air (same source of air as used in air lifts28,40, that is, an externally located, energy efficient regenerative air blower to provide filtered, UV sterilized air) to providebubbles115 for lift as well as for adjusting pH and selectively providing CO₂for the algae or other biomass flowing through theauxiliary vessel80. The pressurized air bubbles provide a positive pressure within the auxiliaryflat panel vessel80, which creates pressure within the enclosures to lift the water and return the oxygen/CO₂enriched fluid biomass back to the top of the core bioreactor containment vessel. The exemplary embodiment of the present invention utilizes a diffuser hose114 (for example, a SIEMENS brand FLEXLINE™ fine bubble diffuser hose), providing air bubbles as well as CO₂to the system when required, while enhancing flow/lift in theauxiliary vessel80 enclosures, as well as circulate the biomass between the core reactor (containment vessel2) and the auxiliary vessel without necessarily the need for an electrical pump.
• A bellows ordiaphragm pump119, may also be used to supplement or replace the air/CO₂injection system within the panel enclosure to move the biomass through theperforated line109 into the flat panel enclosure, as shown in the exemplary embodiment from the core reactor (containment vessel2) and assist the return of the biomass liquids back to the top of the core reactor thus creating a continual circulation of fluid biomass.
• The fluid borne biomass, upon being ejected through theperforated line109, commingles withbubbles115, then flows upward to the second, upper ends104,104′ of each of theenclosures84,84′ respectively, where the fluid borne biomass and bubbles115 flow out105 of each of the first84 and second84′ enclosures viapipes116,116′ where each of the flows are joined107 to return to the upper portion108 of the core reactor, where the fluid borne biomass and bubbles are returned into the annulus between the inside wall of thecontainment vessel2 and flowtube22, for reincorporation into the core bioreactor flow and further EMF bio-stimulation and organism growth control is maintained as previously discussed.
• The fluid borne biomass, when pumped (or circulated via hydrostatic pressure) into theflat panel enclosure80, for example, may pulse by diaphragm pump pressure into the enclosure via theperforated line109,109′, which, with the air/CO₂bubbles115, createsturbulence125 inside of theenclosures84,84′ to enhance photon contact from natural or artificial light energy beamed into the enclosures. The flow in the enclosures may also be pressurized with the air/fluid borne biomass, which forces the biomass to flow back to the core reactor via a return pipe as previously discussed. An over-pressure relief system is utilized to keep the hydrodynamic water pressure from building and blowing out the glass panels, seals, etc., in theauxiliary vessel80, and when activated, circulates the fluid back to the core bioreactor containment vessel, until resuming normal operational pressure. Automated system over pressure alarms also send warning messages via telephone and/or email.
• In theauxiliary vessel80, the injection viadiffuser hose114 of a purified air/CO₂mixture, with the diaphragm pump, provides turbulence to keep the surface clean and keep the debris in suspension; furthermore, rotation in the cell air bubbles keeps the backside of the screen clear. The bubbles provide an airlift action to the biomass from the core reactor, fill up the panel full of water, and pump the fluid borne biomass with bubbles to the top and out of theauxiliary vessel80, so the diffuser air in effect can “pump” the biomass laden fluid without the need for a diaphragm, bellows or other pump. As indicated, because theauxiliary vessel80 is a sealed unit, it becomes pressurized and creates enough pressure to lift the water through both panels and into the top of thecore bioreactor1. At an exemplary 65 gallon per minute flow rate, theauxiliary vessel80 can circulate the entire biomass of the main reactor (containment vessel2) every hour or two. Maximum energy efficiency and balance is achieved using the hydrostatic head pressure from thecore bioreactor1 to fill theauxiliary vessel80 in combination with the air pressure created via thediffuser hose114 inside of theauxiliary vessel80 to generate pressure to lift the biomass back to thecore bioreactor1, creating a continuous flow of biomass between the units. Such a configuration allows for proper circulation of the system without the need for additional energy expenditure required of circulation pumps.
• As shown, theauxiliary vessel80 is positioned so that the plates face the arc of the sun as it tracks across the sky. Such an arrangement would, naturally, be positioned so that it is directly exposed to the sun and ideally maintained via a motorized sun tracking device. It is estimated that approximately 100 of the bioreactors described in the present invention, arranged and operating in serial production mode, have the potential to produce some 100 or more barrels per day of algae bio-crude, in addition to 10 metric tons of a concentrated algae biomass, useful for environmental waste filtering, pharmaceutical, and human or animal nutrition applications.
• As shown inFIGS. 22 and 23, for example, a large number of 4000 or larger gallon bioreactor containment vessels U can be placed within a building B with a corresponding number of the flat panel enclosures F (i.e., auxiliary vessels) on the roof R for concentrating solar energy circulated below into the algae biomass bioreactor system inside of a temperature controlled building, with the top portion (domes) D of the bioreactor containment vessel U penetrating the roof R to capture the natural sunlight. Many other applications and locations are suitable in both cold and warm weather climates.
• In the bioreactor system of the present invention, a recirculating air collection system in the form of a collection conduit in the upper portion of thebioreactor1 can be used to collect air contained in the airspace (including oxygen (O₂which may be generated by algae or other plant organisms) above the water level and in the top portion. The air may be passed through a membrane CO₂/O₂separator or the like, where the CO₂and O₂may be separated and O₂stored, utilized, or vented, while the CO₂may be stored and selectively re-circulated into the bioreactor via the CO₂infusion array29 (FIG. 4).
• Furthermore, the bioreactor system may also be adapted for collecting CO₂and/or other pollutants to prevent emissions into the environment/atmosphere. For instance, an array of bioreactor systems may be configured and arranged at a factory location, such as a cement or power plant, that typically produces CO₂and other pollutants as a waste product. The bioreactor system(s) can be adapted for collecting such waste products to feed the biomass, as well as acting as a biomass processor, resulting in oxygen production and/or biomass to be collected and utilized for various purposes as described herein.
• Exterior systems to support the core bioreactor of the present system include a control system for the lower and upper airlifts which provides forced air thereto on demand via an air-supply line for a regenerative blower system. The system preferably includes as a feature, air purification (via air filtration—four air filters in the exemplary embodiment and UV sterilization) associated with the regenerative air blower.
• Also provided exterior the bioreactor system1000 are CO₂/pH monitors to monitor the CO₂and pH levels in the system and control output of CO₂via the CO₂infuser within the flow tube (or via CO₂added to the air upper or lower airlifts, depending upon the application), an automatic water heater/cooler systems for maintaining optimal temperature of the growth medium/fluid in the system1000, regenerative blowers, and electrical supply and switching devices. If the pH goes over 8.5 in the system1000 when cultivating species of algae, for example, the system can be set to adjust the pH downward to 8.4 or 8.2 pH by injecting CO₂.
• A liquid carbon dioxide storage container or other CO₂source for regulated dispersing of CO₂into the bioreactor system1000 via the CO₂infuser in theflow tube22, with a control module receiving CO₂and pH information from sensors at the bioreactor system1000, automatically controls pH levels in the growth medium during cell growth via the CO₂infusion system, referenced above.
• As the present system utilizes a controlled, sterile atmosphere including forced air (via theairlifts28,40) for circulation, it is important to maintain a positive pressure within thebioreactor containment vessel2 to prevent contamination from outside the atmosphere.
• As the system is pressurized (for example, at up to about 10 PSI), it is important to incorporate a pressure relief mechanism into the system to avoid over pressurization. Accordingly, two (2) pressure-relief systems in the present exemplary embodiment run from line vents in the top portion8 (dome area) of the corebioreactor containment vessel2 and down the side (east side in the exemplary embodiment) of the unit as primary and secondary vessel pressure controls, respectively. Also, a pressure-lock valve may be provided to open and close the vent for venting and pressurization, respectively.
• It is important to note that the airlift system discussed above is not only desirable, but provides a unique, non-destructive system to circulate the fluid/algae suspension within the bioreactor system and between the auxiliary vessel, as algae and many other micro-organisms which can be propagated within this system may stop reproducing or die when subjected to the high-stress velocities created in centrifugal type pumps.
• For this reason, any pumping into or out of the system1000 preferably does not use centrifugal or impeller-type pumps, instead utilizing a more gentle diaphragm or bellows-type water pumps.
• Also not shown is a separate, exterior fiberglass growth medium preparation and holding tank which may be used to prepare the growth medium and other preparation and treatment steps involving the transfer of sterilized freshwater or seawater prior to incorporation into the growth medium.
• In order to monitor the bioreactor contents during production, high-side and low side specimen monitoring and sampling unit ports are provided exterior the corebioreactor containment vessel2 of the exemplary embodiment of the present invention. Also, a valve controlled passage may be provided through the corebioreactor containment vessel2 for a fluid injection (for injecting fluid into the system1000) or drainage system (to drain from the system1000), which can be selectively controlled via valves and tees.
• In addition, an algal-filtration system return line62 (FIG. 1) and valve is provided for returning growth medium back into thebioreactor containment vessel2 after organism filtration.
• Referring toFIG. 8,heat exchangers78,78′, or the like, can be provided to form a longitudinally-situated central passage through thebioreactor containment vessel2, for adjusting the temperature of the fluid therein while forming the central column for circulation within thebioreactor containment vessel2.
• As discussed, the cell division rate in the present embodiment can be monitored by a continuous digital cell-counting device, referenced in the exemplary embodiment as the FLOWCAM™ imaging system, which utilizes flow cytometry and microscopy and automatically counts, images, and analyzes the cells in a discrete sample or a continuous flow, providing data instantly to allow monitoring of cellular health and growth rates up to 500 million cells per milliliter of fluid.
• A growth medium supply line, or other line from thecontainment vessel2, can thus be used to provide samples for electronic laser particle counting, to automatically determine the cell size, as well as count the number of cells per milliliter of water, providing valuable information for monitoring and cultivating the species within the bioreactor system with maximum efficiency.
• For processing algae or other appropriate matter which has been harvested by the present system, the CATLIQ™ brand or other biomass conversion systems may be used to convert the wet algae biomass into bio-crude oil for further refinement into green fuels, nutrients and valuable chemicals.
• Other exemplary embodiments and uses of the present invention are described below. The system may further include a power-washing system built into the upper and lower sections of thecore bioreactor1 andauxiliary vessel80 inner body for the purpose of cleaning and for chemical sterilization of each of the component bioreactors within the system, in which numerous high-pressure spray nozzles are provided and strategically located in each half of the bioreactor. The power-washing system may be powered by, for example, a high (for example, 5,000-PSI) pressure washer.
• An exemplary embodiment of the present invention utilizes multiple fiberglass storage tanks for sterilizing sea water, mixing nutrients and chemicals prior to and during the initial or final biomass growing process, as well as for temporary holding of the biomass that supplies the core or auxiliary vessels, or while servicing the bioreactor systems. The same regenerative blower which supplies the airlifts in the core bioreactor as well as the auxiliary vessel is also used to provide in the present system air and CO₂injection and turbulence in the referenced fiberglass storage tanks; thus, only a single regenerative blower is required to support the entire referenced system of this exemplary embodiment of the present invention.
• As discussed previously, a transparent dome of acrylic or the like may be provided for allowing natural solar light transmission into the top of the tank forming the bioreaction chamber. In addition, a transparent dome may also be provided at the distal, lower end of the tank also formed to enhance natural light exposure within the bioreactor containment vessel. In an alternative to the LED encased domes disclosed above, light ports may be formed in nontransparent components forming the bioreactor vessel, and/or artificial lights (such as the LED capable of producing the desired wavelength to provide photons of the proper frequency for facilitating photosynthesis and proper intensities) may be provided for providing a photon source to the system on a continuous basis. Furthermore, a clear acrylic cylinder may be placed between the upper and lower body sections to add additional 360 degree natural solar energy penetration through the center of the bioreactor, while filtering unwanted UV and IR radiation from the bioreactor and minimizing heat delivery.
• A nitrite-sensor probe and automated liquid nitrite pump system may be provided to monitor and control the amount of nutrient feed that is automatically pumped (via nitrogen or other sources) into the system to optimize the feeding of the organisms as required during various stages of cellular growth. A separate supply tank to feed the core bioreactor with liquid fertilizer from the nitrate sensor triggers the supply pump that administers liquid fertilizer and then shuts down the fertilizer pump. The nitrogen feeder line would go into the core reactor via a line inserted into the discharge side of the pump just upstream of the pH probe. The nitrogen probe arrangement is similar to the arrangement of the pH monitoring probe and CO₂control/injection system.
• A CATLIQ™ biomass conversion system, or the like, would be acceptable to make the wet algae biomass into bio-crude oil for further refinement into green fuels, nutrients and chemicals.
• Exemplary Specification:
• Organism:Nannochloropsis oculata
• Photon exposure: 52 μmol photons m⁻²s⁻¹
• Temperature: 21° C.
• pH: 8.4 (can vary slightly)
• Aeration: 14.7 VVH
• Referring to FIGS.24 and24A-24C, a flow diagram is shown for an exemplary embodiment of the present invention, having electrical data as follows:
• Item A1 (3 Tanks) 1 Each 40Watt 120 Volt
• Four foot Fluorescent Fixture @UV Rated Fluorescent Grow Light, 100 Watt Each, controlled by timer or photocell, 3000watts 120 Volts, 2.5 Amps;
• Item A2 Bio Plate Filter, 2 Each, 5 Lamp, 40 Watt. Eight foot fluorescent fixture 200 Watts each 1.7 amps,
• 2 GA: Ft Strip Fixture, Fitted Two 90 Watt LED Grow Light Module 180 Watts, 1.5 amp.
• Total Item A2 Load 3.2 Amps (may be controlled by Timer or Photo Cell);
• Item A3 Bio Reactor, 18 Each 90 Watt LED Grow Light Controlled by Photo Cell or Timer, 1620Watts 120 Volt, 13.5 Amps;
• Item A4 Sand Filter, 2 Each Fractional HP Pump 9.9 Amp
• Ratio@4.5 Amps 120 v each;
• Item A5 Diaphragm Pump 1HP@120 Volts, 16.0 Amp;
• ItemA6 Blower Motor 4 Vz HP@240 Volts, 19.6 Amps
• One each arrayUV Sterilizing Lamp 120 volt 0.83 Amps
• Total 20.4 Amps.
• Since many modifications, variations and changes in detail can be made to the described embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents.

Claims (30)

What is claimed is:

1. A bioreactor system, comprising:

a containment vessel having a wall having inner and outer sides forming an interior having an inner diameter, lower and upper ends, and a medial area therebetween; and

a generally vertically oriented flow tube positioned in said interior of said containment vessel, said flow tube forming a longitudinal passage having a bottom, a top, and a medial area therebetween; wherein said containment vessel and said flow tube are collectively structured to facilitate the circulation of fluid biomass between said interior of said containment vessel and said longitudinal passage of said flow tube.

2. The bioreactor system ofclaim 1, wherein said flow tube has laterally formed therethrough, in the vicinity of said medial area of said longitudinal passage, a medial flow passage; and a gate valve configured to slidably engage said wall of said flow tube so as to selectively block flow through said medial flow passage upon said interior of said containment vessel being filled to a predetermined fluid level.

3. The bioreactor system ofclaim 1, further comprising at least one auxiliary vessel in fluid communication with said containment vessel, said auxiliary vessel having first and second panels mounted in a spaced fashion to define an enclosure therebetween, at least said first panel formed of light permeable material;

wherein said enclosure is configured to receive a flow of fluid biomass from said containment vessel, and said auxiliary vessel is configured to facilitate the passage of the flow of fluid biomass through said enclosure so as to receive light energy radiating therein.

4. The bioreactor system ofclaim 3, wherein said auxiliary vessel further comprises a diffuser in communication therewith for facilitating the flow of the fluid biomass from said enclosure to said containment vessel.

5. The bioreactor system ofclaim 3, further comprising an artificial light source disposed to project light through at least one of said first and second panels into said enclosure, so as to radiate light energy into said enclosure.

6. The bioreactor system ofclaim 3, further comprising a pump configured to facilitate flow of fluid biomass between said containment vessel and said auxiliary vessel.

7. The bioreactor system ofclaim 3, further comprising at least one linkage tube in fluid communication with said containment vessel and said flat panel enclosure.

8. The bioreactor system ofclaim 7, wherein said at least one linkage tube further comprises a plurality of magnetic rings concentrically mounted thereon, said magnetic rings mounted in spaced fashion along a length of said linkage tube to selectively provide a tunable magnetic field within said linkage tube.

9. The bioreactor system ofclaim 7, wherein said at least one linkage tube further comprises a solenoid coil concentrically mounted thereon to selectively provide a tunable magnetic field within said linkage tube.

10. The bioreactor system ofclaim 1, further comprising at least one bio-stimulation conduit containing a first conduit portion and a second conduit portion, said first and second conduit portions in fluid communication with said containment vessel to form a closed loop, said bio-stimulation conduit further including a plurality of magnetic rings concentrically mounted thereon, said plurality of magnetic rings mounted in spaced fashion along a length of said bio-stimulation conduit to selectively provide a tunable magnetic field within said bio-stimulation conduit.

11. The bioreactor system ofclaim 1, wherein said flow tube has attached thereto a lower stop positioned below said medial flow passage to support said sliding gate valve in a position such that fluid passes through said medial flow passage of said flow tube.

12. The bioreactor system ofclaim 1, wherein said flow tube has attached thereto an upper stop positioned above said medial flow passage to stop upward migration of said sliding gate valve and position said sliding gate valve to block said medial flow passage formed in said flow tube, so as to substantially prevent the passage of fluid therethrough.

13. The bioreactor system ofclaim 1, further comprising a lower airlift in said flow tube positioned below said medial area of said flow tube, said lower airlift formed to provide a pressure gradient to provide fluid lift in said flow tube.

14. The bioreactor system ofclaim 1, further comprising an upper airlift in said flow tube above said medial area of said flow tube, said upper airlift formed to provide a pressure gradient so as to provide fluid lift in said flow tube.

15. The bioreactor system ofclaim 1, further comprising first and second coils concentrically mounted to said flow tube, said first and second coils mounted in spaced fashion along a length of said flow tube to selectively provide a tunable electromagnetic field within and about said flow tube.

16. The bioreactor system ofclaim 15, wherein said first and second coils comprise a Helmholtz coil.

17. The bioreactor system ofclaim 1, further comprising a top portion disposed at said upper end of said containment vessel, said top portion being transparent to light and defining a headspace above said top of said flow tube whereby fluid biomass flowing from said top of said flow tube is exposed to light.

18. The bioreactor system ofclaim 1, further comprising a millimeter wave emitter disposed at the upper end of the containment vessel and configured to project millimeter waves into said containment vessel such that flow from said top of said flow tube is exposed to the millimeter waves.

19. The bioreactor system ofclaim 1, further comprising a carbon dioxide infusion array in communication with said flow tube for infusing carbon dioxide into said flow tube.

20. The bioreactor system ofclaim 1, wherein said wall of said containment vessel has ports formed therethrough, each of said ports covered via a port cover formed of fluid impermeable, light transmissive material.

21. The bioreactor system ofclaim 20, wherein at least one of said ports further comprises an artificial light source mounted so as to project light into said interior of said containment vessel.

22. The bioreactor system ofclaim 1, wherein the inner diameter of said interior of said containment vessel at said lower and upper ends is less than the inner diameter of said containment vessel at said medial area, such that longitudinal flow of matter between said inner walls of said containment vessel and said flow tube encounter an increase in turbulence.

23. A bioreactor system having a top side and underside, comprising:

first and second panels configured in a spaced fashion onto a frame so as to define an enclosure therein, said enclosure having first and second ends, said first panel defining the top side, said second panel defining the underside;

a first tube configured with apertures along its length to disperse fluid biomass into said enclosure, said first tube disposed along said first end of said enclosure;

a second tube configured with apertures along its length to disperse gas into said enclosure, said second tube disposed proximal to said first tube;

wherein said enclosure is configured to facilitate the flow of fluid biomass within said enclosure so as to receive light energy radiating therein.

24. A method of cultivating one or more organism in a biomass, comprising the steps of:

filling a bioreactor with a starter culture of a biomass suspended in a fluid; the bioreactor comprising:

a containment vessel having a wall having inner and outer sides forming an interior having an inner diameter, lower and upper ends, and a medial area therebetween;

a generally vertically oriented flow tube positioned in said interior of said containment vessel, said flow tube forming a longitudinal passage having a bottom, a top, and a medial area therebetween;

said flow tube having laterally formed therethrough, in the vicinity of said medial area of said longitudinal passage, a medial flow passage;

a gate valve configured to slidably engage said wall of said flow tube so as to selectively block flow through said medial flow passage upon said interior of said containment vessel being filled to a predetermined fluid level; wherein the starter culture is filled to about the medial flow passage;

effectuating flow of gas in the flow tube at least below the medial flow passage, so as to provide an upward flow such that the upward flow facilitates the flow of fluid through the medial flow passage, out of the flow tube, down the exterior of the flow tube, and back into the bottom of the flow tube in a looped fashion;

monitoring the biomass for growth;

filling the bioreactor to about the top of the flow tube, causing movement of the gate valve into a position so as to block the medial flow passage and urge the flow through the top of the flow tube, down the exterior of the flow tube, and back in through the bottom of the flow tube in a looped fashion.

25. The method ofclaim 24, further comprising effectuating a flow of gas in the flow tube above the medial flow passage, so as to provide upward flow.

26. The method ofclaim 24, further comprising exposing the interior of the containment vessel to one or more magnetic field, so as to stimulate cellular mitosis in the biomass flowing therethrough.

27. The method ofclaim 24, further comprising exposing the interior of the containment vessel to millimeter waves to stimulate cellular mitosis in the biomass flowing therethrough.

28. The method ofclaim 24, further comprising creating an acidic condition in the containment vessel so as to weaken the cellular body of the biomass.

29. The method ofclaim 28, further comprising exposing the interior of the containment vessel to one or more pulsed magnetic field, so as to break the cellular wall of the biomass to separate lipid oil content therein from the cellular body of the biomass.

30. The method ofclaim 28, further comprising exposing the biomass to millimeter waves tuned so as to provide a pulsed field at a frequency and field strength to break the cellular wall of the biomass to separate lipid oil content therein from the cellular body of the biomass.

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