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Combined Algae Processing (CAP): Progress, Challenges, Opportunities, and Future Directions

This white paper summarizes the historical progress and perspectives on future opportunities for Combined Algae Processing (CAP), a conversion approach centered around fractionating microalgae biomass and producing a slate of fuels and products. We discuss the critical challenges associated with the commercialization of algal biofuels and demonstrate how the CAP approach is uniquely suited to overcome these barriers. The versatility of applying CAP to various sources of algae is highlighted along with conversion to various fuels and product options.

09 BIOMASS FUELS

Algal Biomass Production via Open Pond Algae Farm Cultivation: 2023 State of Technology and Future Research

The annual State of Technology (SOT) assessment is an essential activity for platform research conducted under the Bioenergy Technologies Office (BETO). It allows for the impact of research progress (both directly achieved in-house at the National Renewable Energy Laboratory [NREL] and furnished by partner organizations) to be quantified in terms of economic improvements in the overall biofuel production process for a particular biomass processing pathway, whether based on terrestrial or algal biomass feedstocks. As such, initial benchmarks can be established for currently demonstrated performance, and progress can be tracked toward out-year goals to ultimately demonstrate economically viable biofuel technologies. NREL's algae SOT benchmarking efforts historically focused both on front-end algal biomass production and separately on back-end conversion to fuels through NREL's "combined algae processing" (CAP) pathway. The production model is based on outdoor long-term cultivation data, enabled by comprehensive algal biomass production trials conducted under the Development of Integrated Screening, Cultivar Optimization, and Verification Research (DISCOVR) consortium efforts, driven by data furnished by Arizona State University (ASU) at the Arizona Center for Algae Technology and Innovation (AzCATI) testbed site. The CAP model is based on experimental efforts conducted primarily under NREL research and development projects. This report focuses on front-end algal biomass production, documenting the pertinent algal biomass cultivation parameters that were input to the NREL open pond algae farm model. Through partnerships under DISCOVR, collaborators at ASU furnished details on cultivation performance metrics including biomass productivity and harvest densities for recent growth trials done at the AzCATI site. The resulting biomass productivity was calculated at 16.7 g/m 2 /day (ash-free dry weight [AFDW], annual average) for seasonal cultivation of Picochlorum celeri TG2 and Monoraphidium minutum 26B-AM biomass strains at the ASU site. Picochlorum celeri achieved the best productivity from April to September, with Monoraphidium minutum 26B-AM being used between October and March. Tetraselmis striata LANL1001, usually part of the strain rotation in previous cultivation SOTs, was supplanted by Monoraphidium minutum 26B-AM in this year's outdoor cultivation trials. Finally, building from an industry case study presented in the 2022 SOT report, in the Appendix of this report we provide an update on further improved data furnished by an industry collaborator and resultant impacts on economics reflecting several seasonal scenarios. This case study provides a supplementary datapoint on work being performed elsewhere with a more dedicated focus on improved compositional quality, producing biomass enriched in lipids as may be more optimal for conversion upgrading to fuels and products.

09 BIOMASS FUELS

Technology Case Study: Techno-Economic and Life Cycle Analysis for Microalgae Conversion Pathways to Fuels and Products

This technology case study report details the cost and sustainability prospects for an emerging feedstock - microalgae - converted to fuels and products via a fractionation and upgrading approach termed combined algae processing (CAP). Detailed techno-economic analysis (TEA) and life cycle analysis (LCA) are conducted for the conversion of farmed algae biomass, with two primary scenarios considering the conversion of either high-compositional-quality biomass enriched in lipids (high-lipid [HL]) or lower-quality biomass enriched in protein (high-protein [HP]). Each scenario employs a different biorefinery configuration tailored towards extracting the maximum value from the given biomass composition. The HL scenario produces fuels and non-isocyanate polyurethane (NIPU) as the primary products, while the HP scenario products fuels and a residual solid coproduct which can be used as a co-feed for producing thermoplastics. The results for the HL scenario were particularly promising, with a minimum fuel selling price (MFSP) of $\$$3.68 per gasoline gallon equivalent (GGE) and fuel GHG emissions translating to 54%-76% reduction compared to petroleum fuels depending on the coproduct handling method used. In contrast, the HP scenario faced more challenges in producing biofuels economically, projecting an MFSP of $\$$7.92/GGE despite significant revenues from the residual algae solids. LCA results for the HP case reflected a 24% reduction potential in biorefinery-level GHG emissions. However, these GHG reductions were primarily associated with the thermoplastic coproduct, which accounted for 93% of all biorefinery outputs by mass. Using a process-level allocation method, carbon intensity results were less promising, indicating a net increase in fuel GHG emissions versus petroleum fuels and highlighting the reliance of this scenario on the thermoplastic coproduct.

09 BIOMASS FUELS

Bioregenerative life-support systems

Long-duration future habitation of space involving great distances from Earth and/or large crew sizes (eg, lunar outpost, Mars base) will require a controlled ecological life-support system (CELSS) to simultaneously revitalize atmosphere (liberate oxygen and fix carbon dioxide), purify water (via transpiration), and generate human food (for a vegetarian diet). Photosynthetic higher plants and algae will provide the essential functions of biomass productivity in a CELSS, and a combination of physicochemical and bioregenerative processes will be used to regenerate renewable resources from waste materials. Crop selection criteria for a CELSS include nutritional use characteristics as well as horticultural characteristics. Cereals, legumes, and oilseed crops are used to provide the major macronutrients for the CELSS diet. A National Aeronautics and Space Administration (NASA) Specialized Center of Research and Training (NSCORT) was established at Purdue University to establish proof of the concept of the sustainability of a CELSS. The Biosphere 2 project in Arizona is providing a model for predicted and unpredicted situations that arise as a result of closure in a complex natural ecosystem.

NASA Discipline Life Support Systems

Water Purifier

The Floatron water purifier combines two space technologies - ionization for water purification and solar electric power generation. The water purification process involves introducing ionized minerals that kill microorganisms like algae and bacteria. The 12 inch unit floats in a pool while its solar panel collects sunlight that is converted to electricity. The resulting current energizes a specially alloyed mineral electrode below the waterline, causing release of metallic ions into the water. The electrode is the only part that needs replacing, and water purified by the system falls within EPA drinking water standards.

Source record

SAF: a promising approach to meet growing jet fuel demand

SAF provides a promising approach to aid the rising jet fuel demand from increased travel around the world and reduce the lifecycle emissions from the aviation sector. Although the feasibility of SAF pathways has been demonstrated through economic and environmental metrics quantification, the models used to quantify these variables have a high degree of variability in terms of accuracy and thereby reliability. To understand how to adopt and commercialize SAF, we need to harmonize these process models and assess metrics and technical limitations related to their production technologies. We find the production cost of SAF using hydro processed fatty acids and esters (HEFA), Fischer-Tropsch (FT), and alcohol-to-jet (ATJ) to be $\$$3-$\$$6/gallon gasoline equivalent (gge) and life cycle emissions to be lower than Jet A, except for ATJ using corn grain (≤25%). HEFA utilizing oil feedstocks has the lowest production cost (~$\$$2.9/gge) and highest jet yield (>150 gge/dry ton), while FT has the largest emission reduction (94%) compared to fossil jet. A unique contribution of this study is a comparative analysis of metrics related to SAF processes across technical, economic, and sustainability aspects. A cross-comparison of these metrics shows HEFA using fats, oils, and grease have the most favorable ratings, while HEFA using algae and ATJ using corn stover have more neutral and unfavorable ratings, respectively. These ratings can be improved by implementing the right combination of practical and technological advancements.

09 BIOMASS FUELS

Study of life support systems for space missions exceeding one year in duration, phase 1A. Volume 2 - Mission studies

The study covered by this report is a continuation of the work conducted under ' contract NAS 2-3012, Study of Life Support Systems For Space Missions Exceeding One Year In Duration Phase I. The previous work compared biological and chemical food processing systems with a stored food system for hypothetical missions of from 10 to 100 men for one to three years. The follow-on work Phase IA, the subject of this report, reviewed new concepts for waste processing and food manufacture in the closed system such as wastes for radiation shielding, wastes for propulsion, glycerol synthesis using chromatographic reactors, glycerol synthesis using acetylene as an intermediate, animal links, the use of radiophosphors for algae illumination, and new biological system approaches. The most promising of these new concepts were combined with the food producing systems evolved in Phase I and compared for three specific model missions; Earth orbit, lunar and mars. The effects of spacecraft power penalty, leakage rate, radiation shielding requirements and extravehicular expendable requirements were assessed and a cost effectiveness analysis was completed for each mission. The cost analysis compared the launch cost savings of the advanced systems with the R&D costs required to produce a flight ready system. The study results indicate that systems using wastes for radiation shielding, leakage makeup, or EVA expendables are very competitive with the biological and chemical food systems for all missions. The stored food baseline system and wastes for propulsion ranked poorly in the comparison studies.

R. B. Jagow

Iron rescues glucose-mediated photosynthesis repression during lipid accumulation in the green alga Chromochloris zofingiensis

Energy status and nutrients regulate photosynthetic protein expression. The unicellular green alga Chromochloris zofingiensis switches off photosynthesis in the presence of exogenous glucose (+Glc) in a process that depends on hexokinase (HXK1). Here, we show that this response requires that cells lack sufficient iron (–Fe). Cells grown in –Fe+Glc accumulate triacylglycerol (TAG) while losing photosynthesis and thylakoid membranes. However, cells with an iron supplement (+Fe+Glc) maintain photosynthesis and thylakoids while still accumulating TAG. Proteomic analysis shows that known photosynthetic proteins are most depleted in heterotrophy, alongside hundreds of uncharacterized, conserved proteins. Photosynthesis repression is associated with enzyme and transporter regulation that redirects iron resources to (a) respiratory instead of photosynthetic complexes and (b) a ferredoxin-dependent desaturase pathway supporting TAG accumulation rather than thylakoid lipid synthesis. Combining insights from diverse organisms from green algae to vascular plants, we show how iron and trophic constraints on metabolism aid gene discovery for photosynthesis and biofuel production.

59 BASIC BIOLOGICAL SCIENCES

LHCSR1 Functions as a Dimmer Switch for Light Harvesting

In oxygenic photosynthesis, high light leads to a set of photoprotective processes, known as nonphotochemical quenching, that are required for fitness. In moss and algae, the pigment−protein complex, light-harvesting stress-related (LHCSR), is crucial for photoprotection. Acidification of the thylakoid lumen under high light triggers the activation of LHCSR and the conversion of the xanthophyll violaxanthin into zeaxanthin, which is found within LHCSR. These interrelated molecular components combine to turn on a safety valve that dissipates excess energy as heat. Previous studies of detergent-solubilized LHCSR1 found that pH and zeaxanthin regulate distinct quenching sites via the protein conformation. However, protein function in the native membrane environment can be significantly different. In this work, we applied single-molecule fluorescence spectroscopy to LHCSR1 in membrane nanodiscs. The membrane environment enhanced total quenching, regardless of pH or zeaxanthin-binding. pH-dependent quenching was still observed whereas zeaxanthin-dependent quenching was suppressed. Conformational changes also increased in the membrane, establishing that the local environment can change the nature of the equilibrium between light harvesting and photoprotection.

Hoffmann, Madeline P. [Massachusetts Inst. of Tech

Satellite and airborne remote sensing of gross primary productivity in boreal Alaskan lakes

In terrestrial and marine ecosystems, remote sensing has been used to estimate gross primary productivity (GPP) for decades, but few applications exist for shallow freshwater ecosystems.Here we show field-based GPP correlates with satellite and airborne lake color across a range of optically and limnologically diverse lakes in interior Alaska. A strong relationship between in situ GPP derived from stable oxygen isotopes (δ18O) and space-based lake color from satellites (e.g. Landsat-8, Sentinel-2 and CubeSats) and airborne imagery (AVIRIS-NG) demonstrates the potential power of this technique for improving spatial and temporal monitoring of lake GPP when coupled with additional field validation measurements across different systems. In shallow waters clear enough for sunlight to reach lake bottoms, both submerged vegetation (macrophytes and algae) and phytoplankton likely contribute to GPP. The stable isotopes and remotely sensed shallow lake color used here integrate both components. These results demonstrate the utility of lake color as a feasible means for mapping lake GPP from remote sensing. This novel methodology estimates GPP from remote sensing in shallow lakes by combining field measurements of oxygen isotopes with airborne, satellite and CubeSat imagery. This use of lake color for providing insight into ecological processes of shallow lakes is recommended, especially for remote arctic and boreal landscapes.

airborne remote sensing

Unconventional processes for food regeneration in space - An overview

Alternatives to conventional plant agriculture for the regeneration of food during space missions of extended duration are examined. The options considered, which may be used in combination with conventional agriculture, include the production of food from plant wastes, the chemical synthesis of food from carbon dioxide and other simple molecules or the substitution of edible chemicals, and the use of microrganisms for food and oxygen regeneration, with suitable processing. A comparison of solar energy conversion efficiencies is presented for nonphotosynthetic bacteria grown on hydrogen and algal systems photosynthetically, and it is shown that hydrogen bacteria are potentially more attractive than photosynthetic algae using artificial light. Weight-volume requirements for the conventional plant, algae and hydrogen bacteria systems are also compared to demonstrate the advantages of microbial systems.

Stokes, B. O.

Hydrothermal liquefaction of wastewater-grown algae to produce synthetic aviation fuel: A combined experimental study and techno-economic assessment

Large-scale algae farms may someday become a consistent source of biomass feedstock for biofuels. Near-term supplies of algal biomass are available at certain water resource recovery facilities as algae cultivation is used as a method for nutrient recovery from specific effluent streams. Algae grown as a service shifts the value to the service rather than its sole use as a feedstock, which could enable the provision of algal biomass at low to no cost to biofuel producers. Hydrothermal liquefaction (HTL) can readily upgrade wet feedstock slurries, such as algae, to produce a carbon-enriched biocrude. The HTL biocrude can be hydrotreated and distilled, producing a variety of distillate fuels, including synthetic aviation fuel (SAF). We present a pathway, showing the experimental production of SAF from wastewater-grown algae via HTL, along with a techno-economic assessment to identify opportunities for process improvements. Critical quality attributes of the SAF, such as density, viscosity, surface tension, and freeze point, were estimated within the expected fuel experience ranges when compared against petroleum jet fuel. The average minimum fuel selling price of fuels from wastewater-grown algae for breakeven economics was $\$9.04$ per gasoline gallon equivalent (GGE). The sale of co-products such as struvite fertilizers and cement additives can add revenue to reduce the net cost. Ultimately, the selling price is influenced by the scale of the HTL processing facility. Adjusting estimations in the process scale, algae yield, and capital cost estimation can lower the price to $\$6.51$/GGE or raise it to $13.07/GGE.

Biofuels

Site-specific Design Case Study for Wet Waste Hydrothermal Liquefaction and Biocrude Upgrading to Hydrocarbon Fuels

Hydrothermal liquefaction (HTL) is a thermal process that converts wet biomass to renewable hydrocarbon fuel blendstocks (i.e., renewable naphtha, renewable diesel, and sustainable aviation fuel (SAF)). It can utilize a wide range of pure and blended wet feedstocks, including sewage sludge from water resource recovery facilities (WRRF), food and agriculture wastes, algae, fats, oils and greases (FOG) and blends of dry and wet wastes/feedstocks. Historically, techno-economic analysis (TEA) and annual state of technology (SOT) assessments with standard economic assumptions used by the Bioenergy Technologies Office (BETO) were conducted for the wet waste HTL pathway leveraging experimental data collected from Pacific Northwest National Laboratory’s (PNNL) continuous flow reactor systems. The objective of the SOT assessment has been to guide and track progress of BETO’s HTL research and development (R&D) toward reduced cost and greenhouse gas (GHG) emissions for the pathway. However, gaps exist between BETO’s traditional SOT updates and the needs of key external stakeholders that – if addressed – will accelerate technology adoption. This Business Case Study aims to bridge this gap by providing an updated design, TEA, and LCA based on PNNL’s FY23 R&D with added analyses and information that provide enhanced relevance for stakeholders of the HTL technology. This includes specific siting, regional wet waste resource inventory and transportation cost analyses, fuel market information, sustainable fuel policy impacts, economic metrics of net present value (NPV) and internal rate of return (IRR), greenhouse gas (GHG) emissions analysis, and statistical analysis of cost and technical uncertainties of the HTL plant design. The study focuses on the “Detroit combined statistical area (CSA)” region for siting of a wet waste HTL plant adjacent to the Great Lakes Water Authority (GLWA) facility with guidance from industry participants. Regional resource and siting analyses were conducted to identify feedstock availability, scale, and cost, as well as a beneficial site location. TEA with detailed rigorous capital cost estimation for the specific site application was conducted to evaluate the key economic metrics of most value to industrial partners. These include total capital investment, operating costs, minimum fuel selling price (MFSP) of the biocrude and fuel blendstock, and NPV and internal rate of return IRR with sustainable fuel credits. Life cycle analysis was conducted to evaluate the supply chain greenhouse gas (GHG) emissions for the wet waste HTL process as compared with petroleum derived diesel. This study is also informed by years of R&D and process de-risking learnings and was conducted with a basic engineering HTL plant design and costing that akin to a “first-of-a-kind” plant economics. This differs from our conventional “nth plant ” SOT assessments. Specifically, the HTL process model has been updated with more operationally reliable methods for feed heating and phase separations. Further, we have implemented additional spare equipment for redundancy, a more rigorous installed equipment cost estimation approach, and additional costs associated with feed formatting and delivery, building, piping and site development. An Excel-based cost sheet based on the basic engineering design is also released alongside the report that allows users to conduct customized TEA with their own feed composition and financial assumptions.

09 BIOMASS FUELS

Satellite Radiation Products for Ocean Biology and Biogeochemistry: Needs, State-Of-The-Art, Gaps, Development Priorities, and Opportunities

Knowing the spatial and temporal distribution of the underwater light field, i.e., the spectral and angular structure of the radiant intensity at any point in the water column, is essential to understanding the biogeochemical processes that control the composition and evolution of aquatic ecosystems and their impact on climate and reaction to climate change. At present, only a few properties are reliably retrieved from space, either directly or via water-leaving radiance. Existing satellite products are limited to planar photosynthetically available radiation (PAR) and ultraviolet (UV) irradiance above the surface and diffuse attenuation coefficient. Examples of operational products are provided, and their advantages and drawbacks are examined. The usefulness and convenience of these products notwithstanding, there is a need, as expressed by the user community, for other products, i.e., sub-surface planar and scalar fluxes, average cosine, spectral fluxes (UV to visible), diurnal fluxes, absorbed fraction of PAR by live algae (APAR), surface albedo, vertical attenuation, and heating rate, and for associating uncertainties to any product on a pixel-by-pixel basis. Methodologies to obtain the new products are qualitatively discussed in view of most recent scientific knowledge and current and future satellite missions, and specific algorithms are presented for some new products, namely sub-surface fluxes and average cosine. A strategy and roadmap (short, medium, and long term) for usage and development priorities is provided, taking into account needs and readiness level. Combining observations from satellites overpassing at different times and geostationary satellites should be pursued to improve the quality of daily-integrated radiation fields, and products should be generated without gaps to provide boundary conditions for general circulation and biogeochemical models. Examples of new products, i.e., daily scalar PAR below the surface, daily average cosine for PAR, and sub-surface spectral scalar fluxes are presented. A procedure to estimate algorithm uncertainties in the total uncertainty budget for above-surface daily PAR, based on radiative simulations for expected situations, is described. In the future, space-borne lidars with ocean profiling capability offer the best hope for improving our knowledge of sub-surface fields. To maximize temporal coverage, space agencies should consider placing ocean-color instruments in L1 orbit, where the sunlit part of the Earth can be frequently observed.

Frouin, Robert