INDUSTRIAL PRODUCTION

Cascade Raceways

Tubular Photobioreactors

Flat-Panel Photobioreactors

Fermenters

Tubular Photobioreactors

Tubular Photobioreactors are one of the most used technologies for microalgae production in closed systems.
Ideal for the production of high-value and high-quality products and the production of strains that require a strict control of temperature, or that produce volatile compounds.
The tubes arrangement versatility is an asset for optimal cost-effective production. For instance, it can be designed to act as a solar collector (Unilayer Horizontal Tubular PBR) or provide the highest amount of photosynthetic area using the minimum implantation surface (Multilayer Horizontal Tubular PBR).
A4F has a large experience optimizing this production technology, for different algae species, location, environmental characteristics and type of product / applications of our Customers.

MAIN ADVANTAGES

Fluid flow dynamics: reduction of the reactor zero velocity areas/dead volumes.
Fluid flow dynamics: constant velocity along all the PBR piping extension (> 100 m long).
Optimized global mass and energy balance: O₂, CO₂, nutrients mixing, thermoregulation through internal coils.
Energetic optimization for cost-effective production: efficient circulation pumps.
Improved culture management via parameter control, analysis and fast response: adjust culture circulation velocity, pH, temperature.

MULTILAYER HORIZONTAL TUBULAR PBR
- This configuration comprises several layers of tubes disposed horizontally and parallel to the ground, which means that it has a higher volume to area ratio. This configuration is the most common in the microalgae sector, and has been used for several years in A4F. This configuration allows more flexibility to vary the ratio light/cell and decrease the photo-inhibition effect.
- Ideal for applications with artificial illumination as only or additional energy source, since the area available for artificial light exposure is high, compared to an unilayer configuration.
- Higher ratio volume/area
  - More flexibility to vary the ratio light/cell
  - Temperature is more easily controlled, which might represent an advantage in extreme heat environments
  - Degassing less critical => higher volume for oxygen build-up
UNILAYER HORIZONTAL TUBULAR PBR
- A PBR system developed as an optimization of the multilayer for most applications. Its special configuration comprises one sole layer of tubes disposed horizontally and parallel to the ground, which maximizes the available radiation per cell, enabling a very high photosynthetic efficiency; this configuration allows a maximization of the volumetric productivity and consequently higher culture concentrations and a more robust culture; another direct impact of its higher volumetric productivity is the decrease in harvesting costs due to the lower total volume of the culture
- Ideal for cultures growing exclusively with solar radiation
- Lower ratio volume/area
  - Lower amount of water and inorganic nutrients required => reduction of CAPEX and OPEX
  - Higher concentration of the biomass => Better culture conditions and quality => higher annual productivity

Flat-Panel Photobioreactors

FLAT PANEL PHOTOBIOREACTOR (FP-PBR)

This closed photobioreactors offer a solution to improve contamination control and achieve higher volumetric productivities.
Within closed systems, the most versatile and economic system for the cultivation of microalgae is the flat panel PBR constituted by a disposable transparent LDPE film enclosed within a metal frame.

MAIN ADVANTAGES

Lower capital investment (compared to other closed systems)
Easiness of operation possible to produce different microalgae (robust and fragile strains)
Flexibility and the capacity to be scaled-up
No civil construction required aside from a levelled and compacted site

GLASS PANEL PHOTOBIORECTOR (GP-PBR)

A4F’s has developed a special GP-PBR design indicated for very delicate species, where a sterilization process and a complete sealed system is required; this GP is made of glass and high grade stainless steel.
This closed photobioreactor offers a complete solution to contamination control and achieve higher volumetric productivities.
Indicated for GMO species production and species highly sensitive to other organisms.

MAIN ADVANTAGES

Ability to significantly reduce the exposure to other contaminant organisms trough its sealed configuration
Ability to sterilize the materials contacting the culture
Ability to produce high sensitive species with a higher performance
Easiness of operation and the capacity to be scaled-up

Cascade Raceways

Continuous design optimization since 2010 by A4F for cost effective microalgae production considering energetic costs, productivity enhancement and weather specific conditions, such as high rainfall or sand storms.
This improved cascade raceway, deployed in 2014 in the scope of BIOFAT FP7 project, comprises two parallel-sloped ramps with opposite inclination. After this photosynthetic flow path, the culture flows into a covered tank and pumped back to the first sloped ramp.
Typical industrial production modules are 3.000 to 4.000 m².
The CRW tank has the capacity to store the entire culture volume, which enables this type of raceway to be operated outdoors during high precipitation seasons with better culture management. The CRW ramps slope and pump specifications were designed to operate with a reduced film thickness, 3 to 8 cm, which allows an increase in volumetric productivity and a decrease in harvesting costs due to the lower total volume of the culture, when compared with a conventional raceway design, with water columns between 20 and 30 cm.
The CRW special configuration enables it to be operate trough the tank and also bypassing the tank, reducing considerably its energetic requirements.
Ideal for microalgae that grow in selective media and to every weather conditions.
Recommended for intensive microalgae production projects.

MAIN ADVANTAGES

Lower ratio volume/area
- Lower amount of water, and inorganic nutrients required => reduction of operation costs
- Higher microalgae concentration => Better culture conditions and quality => higher annual productivity
Easier CO₂ control and lower O₂ build-up – better cultivation conditions => lower OPEX and higher annual productivity
Culture continuously flows through a pipe => Higher mixing efficiency and ability to control contaminants and optimized culture management
Storage capacity: capacity to protect the culture from extreme environmental conditions => Higher annual productivity and optimized culture management
Adjustable film thickness between 3 cm and 8 cm => optimized culture management

Conventional Raceway

Prefabricated algae ponds that include containment walls, liner, paddle wheels, and optional control systems. Ideal for microalgae that grow in selective media and to install in areas without large climate variations or frequent storms.
Over decades the most common design used for industrial deployment or large areas (over 10 ha up to 100 ha)
Typical industrial production modules are 5.000 m2 and 1.500 m3.
Recommended for wastewater treatment applications.

MAIN ADVANTAGES

Low construction costs (compared to closed systems)
Easiness of operation
Flexibility and the capacity to be scaled-up
Few to none civil construction required aside from a levelled and compacted site

Fermenters

Available in 2018

MAIN ADVANTAGES

Higher biomass densities
Higher biomass productivities
Lower biomass production costs
Lower harvesting costs
Better replicability and scalability

a biotechnology company with more than 15 years of accumulated experience in microalgae R&D, and microalgae production. A4F is specialized in

design, build, operation and transfer of commercial-scale microalgae production units, using different technologies that

better adapt to our Customers’ business. biotechnology microalgae Cascade

A4F

biotechnology company with more than 15

of accumulated experience in microalgae

R&D, and microalgae production.

the design, build,

and transfer of commercial-scale microalgae production units, using different technologies

adapt to our Customers’ business. biotechnology microalgae Cascade Raceways |

is a biotechnology company with more than

15 years of accumulated experience in microalgae R&D, and microalgae production. A4F is specialized in the design, build, operation and transfer of commercial-scale microalgae production

technologies that better adapt to our

Customers’ business. biotechnology microalgae Cascade Raceways | A4F

a biotechnology company

with more than 15 years of accumulated experience in

R&D, and

production. A4F is specialized in the design, build, operation and transfer of commercial-scale microalgae production units, using different technologies that better adapt to our Customers’ business. biotechnology microalgae Cascade Raceways | A4F

is a biotechnology company with more than 15

years of accumulated experience in

microalgae production. A4F is specialized in the design, build,

using different technologies that better adapt to our Customers’ business. biotechnology microalgae Cascade Raceways | A4F

is a biotechnology

than 15 years of accumulated experience in microalgae R&D, and microalgae production. A4F is specialized

the design, build, operation and transfer of commercial-scale

microalgae production units, using different technologies that

better adapt to

Customers’ business. biotechnology microalgae Cascade Raceways |

A4F is

of accumulated experience in microalgae R&D, and microalgae

A4F is specialized in the design, build, operation and transfer of commercial-scale microalgae production units, using different technologies that better adapt to our Customers’ business.

biotechnology microalgae Cascade

Raceways | A4F

a biotechnology company with

microalgae R&D, and microalgae

technologies that better

adapt to our Customers’ business. biotechnology microalgae Cascade Raceways

A4F

A4F is

a biotechnology company with more than 15 years of accumulated experience

microalgae R&D, and microalgae production.

using different technologies that better adapt to

INDUSTRIAL PRODUCTION

Cascade Raceways

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Contacts INDUSTRIAL PRODUCTION Cascade

Raceways Tubular Photobioreactors Flat Panel

Fermenters Cascade Raceways Conventional

versatility asset optimal cost effective

production technology different

species location environmental characteristics

product applications Customers MAIN ADVANTAGES Fluid flow dynamics: reduction reactor zero velocity areas/dead volumes Fluid flow dynamics: constant velocity along piping extension long Optimized global mass energy balance: nutrients mixing thermoregulation

coils Energetic optimization cost effective production: efficient circulation pumps Improved culture management parameter control

fast response: adjust culture circulation velocity temperature MULTILAYER

layers tubes disposed

horizontally parallel ground which means that higher volume area ratio This configuration most common microalgae sector

This configuration

allows more

flexibility vary ratio light/cell decrease photo inhibition effect Ideal applications with artificial illumination only additional energy source since area available artificial

More flexibility vary ratio light/cell

Temperature more easily controlled which

environments Degassing less

volume oxygen build UNILAYER HORIZONTAL TUBULAR system developed

optimization multilayer most applications special configuration

sole layer tubes disposed horizontally parallel ground which

this configuration allows maximization volumetric productivity consequently higher culture concentrations more robust culture; another direct impact higher volumetric productivity decrease harvesting costs lower total volume culture Ideal cultures growing

with solar radiation Lower ratio volume/area Lower amount water inorganic nutrients required reduction

CAPEX OPEX Higher concentration

biomass Better culture conditions quality higher annual productivity Flat

FLAT PANEL PHOTOBIOREACTOR This closed photobioreactors

offer solution improve contamination

economic system cultivation microalgae flat panel constituted disposable

within metal frame MAIN ADVANTAGES Lower capital investment

compared other closed systems Easiness operation possible produce different microalgae robust fragile strains Flexibility capacity scaled civil construction required aside from levelled compacted site GLASS PANEL PHOTOBIORECTOR A4F’s developed special design indicated very delicate

complete sealed system required; this made glass high grade stainless steel This closed photobioreactor offers complete solution contamination control achieve higher volumetric

productivities Indicated species production species highly sensitive other organisms MAIN ADVANTAGES Ability significantly reduce exposure other contaminant organisms trough

culture Ability produce high sensitive species