Transcript Slide 1

Chemical &
Process
Engineering
Microbubbles:
an energy-efficient way to produce biofuels
Will Zimmerman
Professor of Biochemical Dynamical Systems
Chemical and Process Engineering, University of Sheffield
with Dr Hemaka Bandulasena and Dr Jaime Lozano-Parada,
with Mr Kezhen Ying and Mr James Hanotu
and special thanks to Professor Vaclav Tesar, Dr Buddhi Hewakandamby, and
Mr Olu Omotowa (all formerly University of Sheffield researchers).
‘Engineering from Molecules’
Outline
• Why and how microbubbles?
• ALB concept
• Performance studies
• Steel stack gas trials
• Advantages for microbial and mammalian cell ALBs
• Ozone plasma microreactor in the lab (oxidation,
lysing cells)
• Prototype designs
Chemical &
Process
Engineering
‘Engineering from Molecules’
‘Engineering from Molecules’
Why microbubbles?
Steep mass transfer
enhancement.
• Faster mass transfer -- roughly proportional to
the inverse of the diameter
• Flotation separations -- small bubbles attach
to particle / droplet and the whole floc rises
Chemical &
Process
Engineering
‘Engineering from Molecules’
‘Engineering from Molecules’
The Fluidic oscillator
What is it?
No moving part, Self-excited Fluidic Amplifier.
Outlets
Inlet
Mid Ports
Linked by a feedback Loop
Chemical &
Process
Engineering
‘Engineering from Molecules’
‘Engineering from Molecules’
Fluidic oscillator makes microbubbles!
Same Diffuser
Chemical &
Process
Engineering
• 20 micron sized bubbles from 20 micron sized pores
• Rise / injection rates of 10-4 to 10-1 m/s without
coalescence: uniform spacing/size
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• Watch the videos! ‘Engineering from Molecules’
Gas Inlet
Relatively large coalescent and
fast rising bubbles
Production of Mono-dispersed
Uniformly spaced, non-coalescent
Microbubbles
Gas Inlet
Oscillatory Flow
Conventional Continuous Flow
Chemical &
Process
Engineering
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‘Engineering from Molecules’
Bubble size
distribution
Fine mist of bubbles rising from
Micropore Technologies
Metallic membrane diffuser
Chemical &
Process
Engineering
Median: 47 microns
Standard deviation: 20 microns
20 micron sized pores
‘Engineering from Molecules’
‘Engineering from Molecules’
Energetics from pilot plant
Current draw with varying volumetric
flowrate and feedback loop length
Suprafilt layout for 30m^3/h
Master-slave amplifier system
for fluidic oscillator
Chemical &
Process
Engineering
Oscillatory flow draws less power than
steady flow at the same throughput!
‘Engineering from Molecules’
‘Engineering from Molecules’
Air lift loop bioreactor design
Schematic diagram of an internal ALB with
draught tube configured with a tailor made
grooved nozzle bank fed from the two
outlets of the fluidic oscillator.
The microbubble generator is required to
achieve nearly monodisperse, uniformly
spaced, non-coalescent small bubbles of
the scale of the drilled apertures.
Chemical &
Process
Engineering
• Journal article has won the 2009
IChemE Moulton Medal for best
publication in all their journals.
• Designed for biofuels production
• First use: microalgae growth
• Current TSB / Corus / Suprafilt grant on
carbon sequestration feasibility study on
steel stack gas feed to produce
‘Engineering from Molecules’
‘Engineeringmicroalgae.
from Molecules’
Construction
Top with lid
Inner view:
Heat transfer
coils separating
riser /downcomer.
Folded
perforated
Plate m-bubble
generator.
Replaced by
Suprafilt 9inch diffuser
Body / side view
Chemical &
Process
Engineering
‘Engineering from Molecules’
‘Engineering from Molecules’
Growing algae in the lab
Dunaliella salina
Internal of the ALB
Chemical &
Process
Engineering
The gas separator section links the riser to the
downcomer at the top, permitting gas disengagement
and recirculation of fluid. Consequently, this drives a
‘Engineering
from Molecules’
flow from the top of the riser to
the bottom.
‘Engineering from Molecules’
Gas Dissolution
7.4
7.3
7.2
7.1
7
6.9
6.8
6.7
6.6
6.5
6.4
6.3
Day 3
Fluidic Oscillator
Fluidic Oscillator
Day 7
Without Fluidic
Oscillator
pH
Without F.O.
8.4
8.2
8
7.8
7.6
7.4
7.2
7
6.8
6.6
6.4
6.2
0
15
30
45
7.8
Day 10
7.6
Fluidic Oscillator
Without F.O.
7.4
7.2
7
6.8
6.6
6.4
0
Chemical &
Process
Engineering
15
30
45
0
60
60
7.4
7.3
7.2
7.1
7
6.9
6.8
6.7
6.6
6.5
6.4
6.3
15
30
45
Time (minutes)
Day 11
60
Fluidic Oscillator
Without F.O.
0
‘Engineering from Molecules’
15
30
45
60
‘Engineering from Molecules’
Biomass Concentration
Algal biomass / bioenergy production (~30% extra biomass from
CO2 microbubble dosing for only 1 hour per day).
Chlorophyll Content
(μg/ml)
4.00
3.50
With Fluidic Oscillator
3.00
2.50
Without Fluidic Oscillator
2.00
1.50
1.00
0.50
0.00
1
2
3
4
5
7
8
9
10
11
Time (days)
Chemical &
Process
Engineering
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‘Engineering from Molecules’
Current programme of field trials
• Corus: steel plant algal culture
• Aecom: separation/harvesting
• Air lift loop bioreactor development
for biofuels
Approximately
1 cubic metre
cube design with
0.8 m2 square
ceramic microporous
diffusers.
Chemical &
Process
Engineering
‘Engineering from Molecules’
‘Engineering from Molecules’
Weather
24h Mean
Temperature,
oC
Mean
Temperature
during
process,
oC
Gas Flow
rate,
l/min
Bioreactor
Temperature,
oC
CO2 inlet
Temperature,
oC
Algae
growth,
μg/ml
Day
Light
intensity,
kLux
27/04/2010
30.8
6
17.8
80
17.8
22.9
0.446
28/04/2010
36.5
9
18.7
80
18.7
21.1
0.7834
29/04/2010
12.4
9
16
20
19.8
18.2
1.1741
30/04/2010
64.7
6
13.7
50
16.6
15.5
1.1921
01/05/2010
-
5
12
-
-
-
-
02/05/2010
-
5
8
-
-
-
-
03/05/2010
-
3
9
-
-
-
-
04/05/2010
50.2
1
10.2
20
12.9
15.6
1.1992
05/05/2010
31.2
7
13.7
10
15.0
16.3
1.6703
06/05/2010
13.0
6
10.1
70
12.2
15.1
2.4404
Chemical &
Process
07/05/2010
Engineering
20.0
5
10.2
30
from
15.3‘Engineering 16.8
Weather
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Molecules’
4.9205
Overall growth dynamics
T he gr owth of algal c hlor ophy ll c ontent
5.50
5.00
4.50
4.00
ug/ml
3.50
3.00
2.50
2.00
1.50
1.00
0.50
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‘Engineering from Molecules’
Probing operation
29th of April
25
Bioreactor switched off
Stoppage
Stoppage
Concentration, (%)
20
Flow rate = 80 l/min
Leakage in inlet
15
10
Bioreactor switched on
5
0
10:33
11:45
12:57
14:09
15:21
16:33
Time, (hh:mm)
Chemical &
Process
Engineering
Carbon dioxide CO2
Oxygen (O2)
‘Engineering from Molecules’
‘Engineering from Molecules’
Pseudosteady operation
5th of May 2010
25
Bioreactor switched on
Bioreactor switched off
CO2 Inlet = 23.00%
Concentration (%)
20
15
10
5
O2 Inlet = 4.95%
4 h operation
0
10:48
12:00
13:12
14:24
Time, (hh:mm)
Chemical &
Process
Engineering
Carbon dioxide CO2
Oxygen (O2)
‘Engineering from Molecules’
‘Engineering from Molecules’
Features
From the other experiments,
 Microbubbles formed from fluidic oscillation draw 18% less electricity than the same flow
rate of steady flow forming larger bubbles. 1.5-2 bar gauge pressure needed.
 3-4 fold better aeration rates with ~300-500 micron bubbles, up to 50 fold larger with 20
micron sized bubbles
 Very low shear mixing is possible at low injection rates (rise rate 10-4 m/s )
From the air-lift loop bioreactor performance,
 Microbubbles dissolve CO2 faster and therefore increase algal growth.
 Microbubbles extract the inhibitor O2 produced by the algae from the liquid so that the
growth curve is wholly exponential.
 Algal culture with the fluidic oscillator generated bubbles had ~30% higher yield than
conventionally produced bubbles with only dosing of one hour per day over a two week trial
period.
 Bioenergy could become a more attractive option in the recycling of the high
Chemical &
concentration
of CO2 emissions from stack gases (ongoing field trials).‘Engineering from Molecules’
Process
Engineering
‘Engineering from Molecules’
Ozone Kills and
mineralizes!
Ozone dissolves in
water to produce
hydroxyl radicals
One
ozone
molecule
kills one
bacterium
in water!
Chemical &
Process
Engineering
Hydroxyl radical attacks bacterial cell
wall, damages it by ionisation, lyses the
cell (death) and finally mineralises the
contents.
‘Engineering from Molecules’
‘Engineering from Molecules’
Microfluidic onchip ozone generation
Our new chip design and associated electronics produce ozone from O2 with key
features:
1. Low power. Our estimates are a ten-fold reduction over conventional ozone
generators.
2. High conversion. The selectivity is double that of conventional reactors (30%
rather than 15% single pass).
3. Recently discovered strong irradiation in UV “killing zone” of ~300 nm.
4. Operation at atmospheric pressure, at room temperature, and at low voltage
(170V, can be mains powered).
Chemical &
Process
Engineering
‘Engineering from Molecules’
‘Engineering from Molecules’
Plasma discs
• 25 plasma reactors each with treble throughput over
first microchip
Chemical &
Process
Engineering
‘Engineering from Molecules’
‘Engineering from Molecules’
Dosing lance assembly
New lance = 70 microdisc reactors
Quartz for UV irradiation
Axial view of the old lance
With 8 or 16 microdisc reactors
Chemical &
Process
Engineering
‘Engineering from Molecules’
‘Engineering from Molecules’
Consequences
• Our low power ozone plasma microreactor can be
inserted into the microporous diffusers to arrange for
ozone dosing on demand in an ALB, for sterilization
or other uses.
• One potential use is providing a non-equilibrium
driving force for biochemical reaction / biomass
growth by breaking down extracellular metabolites
secreted by microorganisms to minerals (CO2, H2O,
nitrates, phosphates etc.) by UV-ozone providing a
strong oxidizing environment in situ.
Chemical &
Process
Engineering
‘Engineering from Molecules’
‘Engineering from Molecules’
More Acknowledgements
• Corus: Bruce Adderley, Mohammad Zandi and many
more.
• Suprafilt: Graeme Fielden, Jonathan Lord, and
Hannah Nolan
• Micropore Technologies: Mike Stillwell
• HP Technical Ceramics: Tim Wang
• AECOM DB: Brenda Franklin, Ben Courtis, Hadi Tai
• Yorkshire Water: Martin Tillotson, Ilyas Dawood
• UoS: Jim Gilmour, Raman Vaidyanathan, Simon
Butler, Graeme Hitchen, Adrian Lumby, Stuart
Richards,
Clifton Wray, Andy Patrick
Chemical
&
Process
Engineering
‘Engineering from Molecules’
• Yorkshire Forward, TSB, EPSRC, SUEL
‘Engineering from Molecules’
More information
Background information about the Moulton Medal winning paper including a link to a
ereprint.
http://eyrie.shef.ac.uk/steelCO2/awards.html
Videos of microbubbles in various guises
http://eyrie.shef.ac.uk/steelCO2/open/videos
Aeration papers
http://eyrie.shef.ac.uk/steelCO2/open/aerationefficiencypart1.pdf
http://eyrie.shef.ac.uk/steelCO2/open/aerationefficiencypart2.pdf
http://eyrie.shef.ac.uk/steelCO2/open/microbubble generation.pdf
http://eyrie.shef.ac.uk/steelCO2/open/Sensors_and_Actuators.pdf
Plasma papers
http://eyrie.shef.ac.uk/steelCO2/open/reprintkinetics.pdf
http://eyrie.shef.ac.uk/steelCO2/open/Ozone_regenerated.pdf
Chemical &
Process
Engineering
‘Engineering from Molecules’
‘Engineering from Molecules’