Tubular Glass Photobioreactors. Let s bring light to algae.

Transcription

1 Tubular Glass Photobioreactors Let s brg light to algae.

2 SCHOTT is a leadg ternational technology group the areas of specialty glass and glass-ceramics. With more than 130 years of outstandg development, materials and technology expertise we offer a broad portfolio of high-quality products and telligent solutions that contribute to our customers success. With a production capacity of more than 140,000 tons and production sites Europe, South America and Asia, SCHOTT Tubg is one of the world s leadg manufacturers of glass tubes, rods and profiles. More than 60 different glass types are produced a large variety of dimensional and cosmetic specifications based on a standardized production process and a global quality assurance system. SCHOTT Tubg provides customized products and services for ternational growth markets such as pharmaceuticals and electronics as well as dustrial and environmental engeerg. Title Photo Courtesy of ecoduna AG ecoduna.com Pictures on page 6 / 9 Photo Courtesy of Clearas Water Recovery

3 Contents 4 Algae Production Systems 5 Crystal Clear Benefits 7 Product Range Borosilicate Glass Tubg Borosilicate Glass U- and J-Bends Couplgs Borosilicate Glass Manifolds 15 Packagg 18 Closed Tubular Photobioreactors versus Open Ponds 19 Borosilicate Glass versus Polymer Materials 20 Pressure Drop Tubular Photobioreactors 22 References of Glass Tubular Photobioreactors (PBRs) 23 Technical Terms of Supply 16 Borosilicate Glass Properties

4 4 Algae Production Systems Coon photosynthetic algae cultivation systems are either open ponds or closed photobioreactors (PBRs). Open ponds Open ponds are typically built circular or race way configurations. The water is kept motion, for example by paddle wheels. Open ponds are seemgly expensive and easy to build. However, poor light utilization, danger of contamation and high water evaporation are the ma challenges, which lead to low biomass output per area and large water uptake. Some difficulties can be overcome by rooftops however this creases the costs further. Closed system Closed systems are domated by tubular and flat-plate reactors. Other options are bags, coils or domes. Flat plate systems have received a lot of attention due to their large illumated surface area, but the technology suffers from heatg problems and a strong tendency to build up biofilm formations on the ner walls. Tubular systems on the other hand reduce these drawbacks while matag the advantages of optimal light put and high productivity. Therefore closed tubular glass Photobioreactors (PBRs) with long lifetimes and easy cleanability, are very well suited for the highly reproducible cultivation of algae resultg the highest possible growth rates. As such, tubular glass PBRs are best suited to provide bio-security for high quality oculum used open ponds. Upper photo Haematococcus pluvialis, green phase Lower photo Haematococcus pluvialis, red phase

5 5 Crystal Clear Benefits of Closed Tubular Glass PBR Systems Bio-Secure protection agast bio-contamation and culture crashes Productive l/m 2 photoactive volume, PBR height up to 6m Cost Efficient little matenance and low total cost of ownership Durable sustaable light transmission T > 95 % (air-glass-water), lifetime of 50 years and more Resistant agast chemicals, corrosion, saggg, scratches, UV-light Food Safe food and pharma grade Closed Vertical Tubular Glass PBR System ecoduna AG ecoduna.com

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7 7 Product Range Overview Helical System U- or J-Bend 2 Couplg 3 Tubg Fence System horizontal or vertical orientation Manifold 2 Couplg 3 Tubg

8 8 Product Range Borosilicate Glass Tubg DURAN Item No. Jot Outside Diameter Jot Wall Thickness Tube Length Volume per tube Package Type* Package Content ± ± 0.02 Other dimensions upon request. 1.8 ± ± 0.01 m ft l gal carton 9 pallet 180 carton 12 pallet 144 wooden box pallet ± ± ± ± carton 9 pallet 180 carton 9 pallet 108 wooden box pallet ± ± ± ± carton 1 pallet 6 pallet 6 Number of Tubes Weight approx. kg approx. lb * for explanation regardg package type please see page 15

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10 10 Product Range Borosilicate Glass U- and J-Bends DURAN Helical System U-Bend U-Bend long J-Bend Bend Types are used for the followg applications U-Bend: for gaps between tubes of typically 65 /2.56 or more U-Bend long: used combation with J- and U-Bends J-Bend: for smaller gaps down to 40 /1.57 (couplgs are shifted every second row)

11 11 U-Bend Item No. Jot Outside Diameter Jot Wall Thickness Jot U-Bend Width Approx. U-Bend Height Straight Side Length Volume per Bend (approx.) Package Type Package Content ± ± ± ± ± ± > 45 > 1.77 l gal Number of Tubes carton 34 pallet ± ± ± ± ± ± > 45 > carton 21 pallet 189 U-Bend long Item No. Jot Outside Diameter Jot Wall Thickness Jot U-Bend Width Approx. U-Bend Height Straight Side Length Volume per Bend (approx.) Package Type Package Content l gal Number of Tubes ± ± ± ± ± ± > 145 > carton 21 pallet 189 J-Bend Item No. Jot Outside Diameter Jot Wall Thickness Jot U-Bend Width Approx. U-Bend Height Straight Side Length short leg long leg Volume per Bend (approx.) Package Type Package Content l gal Number of Tubes ± ± ± ± ± ± > 45 > 1.77 > 145 > carton 21 pallet 189

12 12 Product Range Couplgs SCHOTT tool kit Open Standard Couplg Open Standard Slim Couplg Specially developed for tubular photobioreactors: The couplgs are designed for SCHOTT glass tubes with pla tube ends accordg to the product range shown this brochure. Successfully tested for 10 years lifetime regardg - 3 bar pressure resistance - UV-resistance - Regular cleang cycles with various chemicals Fast stallation allowg for reduced built up time of the reactor Easy to disassemble and re-use allowg for fast modification or extension of a reactor system Easy handlg with pre-assembled devices and a special tool kit cludg a torque wrench Food grade Note A special tutorial you get on request. Please follow the lk or QR code to watch our tutorial video.

13 13 Item No. Outside Diameter Tube on Side 1 Outside Diameter Tube on Side 2 Package Description Package * Number of Couplgs 24 bag 960 pallet 24 bag 1824 pallet Standard (1) Standard Slim (2) Weight approx. kg approx. lb (1) Standard, length 80 With partition wall to assure glass separation and smooth transition bag 960 pallet 24 bag 1824 pallet Standard (1) Standard Slim (2) (2) Standard Slim, length 45 Toolbox 54 with torque wrench for closg of couplg and tools for openg Toolbox 65 with torque wrench for closg of couplg and tools for openg * available 2018 Additional Equipment Item No. Outside Diameter Tube on Side 1 Outside Diameter Tube on Side 2 Package Description Package (3) Matenance, length 80 Allows easy exchange of tubes, no partition wall Number of Couplgs Weight approx. kg approx. lb 0.9 (no partition wall) (3) carton Matenance kit 576 pallet 4 carton Matenance kit 576 pallet (no partition wall) (3) carton 576 pallet Adapter (4) (4) Adapter, length 80 Allows connection to pheriphery tubes with 2.5 ch outer diameter

14 14 Product Range Borosilicate Glass Manifolds DURAN Fence System Manifolds and Couplgs, Fence System, ecoduna AG ecoduna.com Manifold equipped with a flange Manifold equipped with a closed end Manifolds are placed at the tops or at the ends of tubular PBR fences and function as U-Bends and - and outlets. Bio secure and food safe, full glass solution Available with closed ends or with flange Outside diameter of arms: 54 or 65 for use with standard couplgs Number of arms, distance between arms, total length etc. are customized with a mimum order quantity of 25 pieces Item No. Description Package Package Content Mimum Order Quantity (MOQ) Manifolds 10 arms closed Manifolds 5 arms flange Manifolds 8 arms closed Manifolds 4 arms flange Manifolds 6 arms open 65 carton 2 pallet 18 1 pallet

15 15 Packagg Cartons Tubes, up to 2.5 m length U-Bends Couplgs Manifolds Packagg with cartons Wooden boxes Tubes, 5.5 m length, smaller quantities Packagg with wooden boxes Special Pallets Tubes, 4 m and 5.5 m length Packagg with pallets

16 16 Borosilicate Glass Properties Coefficient of mean lear thermal expansion a acc. to DIN ISO 7991 Metric K -1 (20 C; 300 C) US K -1 (68 F; 572 F) Transformation temperature T g 525 C 977 F Density r at 25 C 2.23 g cm lb ft -3 Modulus of elasticity E (Young s modulus) N lb -2 (psi) Poisson s ratio m Thermal conductivity l w at 90 C 1.2 W m -1 K Btu hr -1 ft -1 F -1 Refractive dex (l = nm) n d Stress-optical coefficient (DIN ) K N N -1 Chemical Composition SiO 2 B 2 O 3 Na 2 O + K 2 O Al 2 O 3 Chemical Resistance Hydrolytic Class (DIN ISO 719) HGB Acid Class (DIN 12116) Class S 1 ma components approx. weight % Alkali Class (DIN ISO 695) Class A 2

17 17 Transmission Note When the glass tube is filled with water, the transmission creases from about 92 % to 95.6 % due to reduced reflection losses at the ner glass/water terface ,000 1,200 Wavelength [nm] 0 Transmission [%] (left scale) Solar irradiation [W. m -2. nm -1 ] (right scale) Transmission of DURAN glass (d=2.2) configuration air/glass/air. Pressure Resistance of Tubg made of Borosilicate Glass The followg formulas apply to stress free, priste tubg and cyldrical hollow bodies with a circular profile, uniform wall thickness with open ends, free from thermal load, under ternal positive pressure. Estimation of the maximum pressure resistance (p) WT 140 bar p = OD WT Estimation of the mimum wall thickness (WT) OD p WT = 140 bar + p OD = Outside Diameter [] WT = Wall Thickness [] p = Pressure Resistance [bar] Other pots to be considered: AD 2000-leaflet N 4, edition : Pressure vessels made of glass, with encl. 1, edition : Evaluation of faults walls of glass pressure contaers AD 2000-leaflet B 1, edition : Cyldrical and spherical shells under ternal pressure overload K S = 70 bar permissible load referrg to standard DIN EN 1595: Pressure Equipment made from Borosilicate Glass 3.3 General Rules for Design, Manufacture and Testg Accordg to DIN EN 1595 Pressure Equipment made from Borosilicate Glass 3.3 General Rules for Design, Manufacture and Testg, DURAN is an approved material and may be used for the construction of pressure equipment.

18 18 Features and Benefits of Closed Tubular Photobioreactors versus Open Ponds Contamation Very low risk of contamation compared to open ponds, where other microorganisms or sects have easy access No limitation regardg the algae species that can be grown, also due to effective blockg agast competg organisms Productivity Higher productivity terms of mass per area and day Significantly higher volumetric productivity Algae concentration at harvest Water loss Notably higher concentration terms of mass per liter More efficient harvestg procedure No evaporation with closed system compared to open ponds, which can lose significant water amounts, resultg salization Water loss is limited to external factors, such as the coolg process Closed tubular photobioreactor Biomass quality Biomass quality is highly reproducible due to excellent process control of tubular PBR systems High value products or high quality oculum can be produced with optimum reliability Production flexibility Easy cleanability allowg for defed itial status any time, thus switchg algae species is possible and secure Open pond Use of GMO* for improved production process GMO production is possible with closed reactor design * GMO = Genetically Modified Organism

19 19 Features and Benefits of Borosilicate Glass versus Polymer Materials Light transmission Excellent light transmission (see page 17 for details) No solarization or browng effect No UV-protective additive or coatg necessary to secure material properties Fire protection Glass does not burn or give off toxic fumes Leachg Glass is a chemically highly resistant material. With plastic tubg, dependg on the polymer type, monomers or oligomers of hazardous substances such as Bisphenolmolecules can be leached to the algae culture. Borosilicate glass Cleang Mechanical stability allows contous -le cleang with polymer pellets Chemical stability allows cleang place (CIP) Lower material and matenance costs compared to quality polymer tubes Thermal stability Cost savg No need for expansion loops due to low thermal expansion Example: for 5.5 m long tubes and a temperature crease of 20 C/36 F the expansion of Borosilicate glass is only 0.36 /0.01 while polymers expand from / dependg on polymer type Glass components can last fifty years and longer Reduced number of rack poles. High mechanical stability allows creased support distances without significant saggg of tubes (see picture on right) Polymer Sag [] Position along tube [m] Glass Tube PMMA Tube Saggg No permanent deformation of glass tubes contrast to polymer tubes Saggg of water filled tubes (outer diameter 65, wall thickness 2.2, length 2.75 m). The sag of the glass and polymer tubes is 0.5 and 6.6, respectively. The polymer tube would need to be supported every 1.5 m for the same sag as the glass tube.

20 20 Pressure Drop Tubular Photobioreactors Dean-vortex appearance an U-Bend computer simulation (ANSYS CFX ) For the optimum construction of a photobioreactor the expected pressure loss the system must be known. This formation is relevant for the lay-out of the ideal pump design. For the calculation of the pressure drop of the entire photobioreactor system the pressure drops of the dividual components can be added together. The dividual pressure drops must be calculated for the desired velocity, u. In the followg table (p. 21) the dividual pressure drops of representative glass components are shown for a typical flow velocity of 0.7 m/s. The pressure drops depend on the dimensionless zeta-values, which slightly decrease at larger velocities. Please contact SCHOTT technical service for assistance and additional simulations.

21 21 Pressure loss In general, the pressure drop can be calculated for any velocity usg the followg formula. Δ p = ζ ρ 2 u2 Δ p: pressure loss ζ : pressure loss number (zeta) ρ: algae culture density u: lear velocity of algae culture u = 0.7 m/s ζ Δ p [Pa] Round Tube (D = 65, WT = 2.2, L = 5.5 m) U-Bend (D = 65, WT = 2.8 ) Pressure drops of a tube and a U-Bend at the given velocity, u. D is the outer diameter, WT the wall thickness. The algae culture s density was approximated with ρ=1 g/cm 3. Electrical Power The electrical power of the pumps, P el, scales with the pressure drop and the volume flow, Q: P el = Δ p Q η p P el : Electrical power Δ p: Sum of pressure loss Pa Q: Volume flow rate m 3 /s η p : Pump efficiency at operatg pot (0 < η p < 1) Research done cooperation with: Institute of Fluid Dynamics, LSTM, Technical Faculty, University Erlangen-Nuremberg, Germany

22 22 References of Glass Tubular Photobioreactors SCHOTT has formed alliances and partnerships all over the world. This allows us to provide complete tubular photobioreactors accordg to your needs. Please contact us for further details. Photo courtesy of Algalif, Iceland Photo courtesy of Varicon Aqua Solutions Ltd, UK Photo courtesy of A4F-Algae for Future, Portugal Photo courtesy of Algatechnologies Ltd., Israel Photo courtesy of Clearas Inc., USA Photo courtesy of ecoduna AG ecoduna.com, Austria

23 23 Please follow the lk or QR code to watch our videos Technical Terms of Supply Detailed formation on permissible faults, defition of faults, testg methods and testg units are available upon request. Reduced tolerances are also available upon request. Regardg quality issues the relevant Technical Terms of Supply for the application apply to all sales and are bdg unless separate written agreements with respect to specification have been agreed upon. SCHOTT is a registered trademark of SCHOTT. DURAN is a registered trademark of DWK Life Sciences GmbH. We thank our customers and partners for their kd assistence providg product samples and photos. SCHOTT decles any liability with respect to the correctness or completeness of any formation or data that is expressly or implicitly contaed this brochure.

24 Tubg SCHOTT North America, Inc. 555 Taxter Road Elmsford, NY USA Phone +1 (914) Fax +1 (914) Aus KW