Haematococcus pluvialis - · PDF fileWith more than 70% of ... Haematococcus pluvialis Green...

Sustainable pilot-scale production of carotenoid

compounds from the green microalga

Haematococcus pluvialis

Paula Pérez-López, Sara González-García, Edward McHugh, Daniel Walsh,

Patrick Murray, Siobhan Moane, Gumersindo Feijoo, Mª Teresa Moreira November 25,

2013

Introduction to microalgal processes

Goal and scope

Inventory analysis

Environmental impact assessment

Conclusions


Goal and scope

Inventory analysis


Conclusions

Contents

USES OF MARINE RESOURCES

Marine biotechnology

Why marine resources?



With more than 70% of

the planet’s surface

covered by water,

oceans are probably the

most promising habitat

to explore for novel

microbial biodiversity.




Marine biotechnology is an emergent sector with an estimated

global market value of 2.8 billion € in 2010 and annual growth of

4.3% during the period 2007-2012.

Pharmacology 32%

Agriculture 2%

Food 6%

Cosmetics 1% Chemistry

54%

Others 6%

Leary et al. (2009). Marine genetic resources: A review of scientific and commercial interest.

Marine Policy 33(2):183-94

0

5

10

15

20

25

30

Nu

mb

er

of

pat

en

ts

Period

% patents in marine biotechnological sector No. patents involving marine resources


SIGNIFICANCE OF MICROALGAL PROCESSES

Products from microalgae MICROALGAE:

One resource, many products...

From Wilkie et al. (2011). Indigenous algae for local bioresource production: Phycoprospecting, Energy Sustain Dev 15(4):365-71

Algae Oils

Proteins Carbohydrates

Biomass

TECHNOLOGICAL OPTIONS

Cultivation systems for microalgae

How to produce microalgae?


Goal and scope

Inventory analysis


Conclusions


Goal and scope

Inventory analysis


Conclusions

Contents

Astaxanthin

Red carotenoid (pigment)

Applications as additive in food industry, cosmetics...

Potential uses in pharmaceutical industry due to its antioxidant,

anti-inflamatory and antitumor properties

CASE STUDY

Pilot-scale production of carotenoids by H. pluvialis


Green microalga

Cultivated in two stages

It accumulates between 1-5%

of astaxanthin

Green phase

Red phase

GOAL AND SCOPE DEFINITION

Objective of the study

Cultivation in Reactor Systems

Wild Marine Organism Harvesting

Harvesting

Extraction and Purification of Biocompounds

End of Life

ASSESSMENT

Distribution

Product Use

Quantification of main environmental impacts associated to the

process

“Cradle-to-gate” perspective (from raw materials to extraction of the

biocompound)

Identification of the most

problematic stages

Proposal of alternative scenarios

to improve the environmental profile

HOT SPOTS

Product Formulation

CULTURE IN TWO PHOTOBIOREACTORS IN SERIES

(1000 L tanks, 2-4 g/L biomass)

HARVESTING

4 kg of biomass (4-5% astaxanthin)

EXTRACTION

Supercritical CO2 Extraction ≈ 800 g astaxanthin


Functional Unit


System boundaries

AIR

, SO

IL &

WA

TER

EM

ISSI

ON

S

FOREGROUND SYSTEM

BACKGROUND SYSTEM

SUBSYSTEM 1: CLEANING OF THE

REACTOR

SUBSYSTEM 2: PREPARATION OF THE CULTURE MEDIUM

SUBSYSTEM 3: CULTIVATION

SUBSYSTEM 4: HARVESTING SUBSYSTEM 5: EXTRACTION RA

W M

ATE

RIA

LS,

WA

TER

& F

OSS

IL F

UEL

S

CHEMICALS (Nutrients & Solvents)

MACHINERY

ELECTRICITY

AIR SUPPLY

REACTOR STERILIZATION (ozonization or

chemicals)

GROWTH STAGE

STRESS STAGE

SETTLING

SETTLING

CENTRIFUGATION

SPRAY DRYING

SUPERCRITICAL FLUID EXTRACTION

AST

AX

AN

THIN

(10

%

IN O

LEO

RES

IN)

WA

STE

TO

TREA

TMEN

T

BY

- P

RO

DU

CT

(FER

TILI

ZER

)

REVERSE OSMOSIS

FILTER

UV FILTER

ADDITION OF NUTRIENTS AND

INOCULUM

WATER SUPPLY


Goal and scope

Inventory analysis


Conclusions


Goal and scope

Inventory analysis


Conclusions

Contents

INVENTORY ANALYSIS

Data sources

GENERAL INFORMATION

Partner

Objective

Production Extraction/Purification

Type of marine organism (please tick the appropriate box

)

Microalgae Marine sponges

Macroalgae Epiphytic bacteria

Marine fungi and marine protists

Scientific name

Bioactive compound

Alternative producer/producers of the compound

Cultivation method (please tick the appropriate box )

Open raceway ponds Shore base farming

Photobioreactor Traditional biofermenter

Tubular reactor Tissue culture

Other:...........................................................................

Field data (Surveys to

producers)

Databases

Bibliographic sources

INPUTS from TECHNOSPHERE

Materials

Cleaning of the reactor OPTION 1 for reactor sterilization OPTION 2 for reactor sterilization

Tap water (cleaning) 4,009 L Stainless steel 0.200 kg NaClO 4.009 kg

Preparation of the culture medium Preparation of the culture medium NaNO3 4.4651 kg Stainless steel 0.3446 kg K2HPO4 0.9121 kg PVC 0.0213 kg KH2PO4 0.4041 kg UV lamps 0.0175 kg CaCl2 0.2914 kg Polyamide 0.1169 kg MgSO4 1.3473 kg Cultivation NaCl 0.1194 kg Stainless steel 8.36 Kg C6H8O7 0.0287 kg Reactor lamps 0.13 Kg C6H5+4yFexNyO7 0.0287 kg Harvesting Na2CO3 0.4778 kg Stainless steel 3.84 kg C10H16N2O8 0.0263 kg Extraction H3BO3 0.0137 kg Drying agent 35.46 kg ZnSO4 0.0011 kg Co-solvent 4.67 kg CuSO4 0.0004 kg Stainless steel 0.55 kg Co(NO3)2 0.0002 kg FeCl3 0.0028 kg ZnCl2 0.0001 kg CoCl2 0.0001 kg MnCl2 0.0098 kg Na2MoO4 0.0012 kg

INPUTS from TECHNOSPHERE

Energy Transport Distance (km)

Total electricity from Irish grid 1,982.37 kWh Cleaning of the reactor 1,982.49 kWh (OPT. 2) OPTION 1 Lorry, 3.5-7.5 t, Euro 4 3.207 tkm 600

Chemicals Ship 5.613 tkm 1400 Cleaning of the reactor OPTION 2 Lorry, 3.5-7.5 t, Euro 4 0.120 tkm 800 OPTION 2 for reactor sterilization Equipments Ship 0.281 tkm 1400 Reactor sterilization 0.12 kWh Preparation of the culture medium

Preparation of the culture medium Chemicals Lorry, 3.5-7.5 t, Euro 4 6.504 tkm 600 Reverse osmosis filtration 7.71 kWh Ship 11.382 tkm 1400 UV filtration 0.35 kWh Equipments Lorry, 3.5-7.5 t, Euro 4 0.300 tkm 800

Cultivation Ship 0.700 tkm 1400 Reactor lighting 1,539.43 kWh Cultivation Air blowing 96.21 kWh Equipments Lorry, 3.5-7.5 t, Euro 4 5.091 tkm 800 Agitation 96.21 kWh Ship 11.879 tkm 1400

Harvesting Harvesting Centrifugation (harvesting) 1.50 kWh Equipments Lorry, 3.5-7.5 t, Euro 4 2.305 tkm 800 Spray drying 82.70 kWh Ship 5.379 tkm 1400

Extraction Extraction Supercritical CO2 extraction 158.25 kWh Chemicals Lorry, 3.5-7.5 t, Euro 4 32.098 tkm 600

Ship 56.171 tkm 1400 Equipments Lorry, 3.5-7.5 t, Euro 4 0.330 tkm 800

Ship 0.771 tkm 1400 Final disposal

Solid waste Lorry, 3.5-7.5 t, Euro 4 2.442 tkm 50 2.452 tkm (OPT. 2)

INPUTS from ENVIRONMENT Preparation of the culture medium Cultivation

Biomass inoculum 0.02 kg CO2 26.44 kg River/rain water 2,786 L

OUTPUTS to TECHNOSPHERE

Products

OLEORESIN (10% astaxanthin) 8.00 kg

Pure astaxanthin 0.80 kg Co-solvent 7.16 kg

Impurities 0.04 kg

Avoided product (fertilizer)

Cell paste 20.516 kg

N fertilizer 0.431 kg ammonium sulfate, as N

P fertilizer 0.282 kg diammonium phosphate, as P2O5

Waste treatment

Steel, to inert landfill 13.29 kg

Polyvinyl chloride, to sanitary landfill 0.02 kg

Fluorescent lamps, to specific treatment for electronics wastes 0.15

kg

Textiles, to municipal incineration 0.12 kg

Diatomaceous earth, to inert landfill 35.46 kg

OUTPUTS to ENVIRONMENT

Water emissions

Cleaning of the reactor (OPTION 1) Harvesting Extraction Wastewater 4,009 L Wastewater 1,001.30 L Wastewater 0.93 L

NaClO 4.009 kg NaNO3 1.7522 g NaNO3 1.6329 mg

Cultivation K2HPO4 0.0080 g K2HPO4 0.0075 mg Wastewater 1,783.98 L KH2PO4 0.0035 g KH2PO4 0.0033 mg

NaNO3 87.3400 g CaCl2 0.6108 g CaCl2 0.5692 mg

K2HPO4 19.4050 g MgSO4 2.8237 g MgSO4 2.6313 mg

KH2PO4 8.5970 g NaCl 0.2503 g NaCl 0.2333 mg

CaCl2 3.4848 g C6H8O7 0.0601 g C6H8O7 0.0560 mg

MgSO4 16.1100 g C6H5+4yFexNyO

7 0.0601 g C6H5+4yFexNyO

7 0.0560 mg

NaCl 1.4282 g Na2CO3 1.0013 g Na2CO3 0.9331 mg

C6H8O7 0.3428 g C10H16N2O8 0.0551 g C10H16N2O8 0.0513 mg C6H5+4yFexNy

O7 0.3428 g H3BO3 0.0286 g H3BO3 0.0267 mg

Na2CO3 5.7127 g ZnSO4 0.0022 g ZnSO4 0.0021 mg

C10H16N2O8 0.3142 g CuSO4 0.0008 g CuSO4 0.0007 mg

H3BO3 0.1634 g Co(NO3)2 0.0005 g Co(NO3)2 0.0005 mg

ZnSO4 0.0126 g FeCl3 0.0058 g FeCl3 0.0054 mg

CuSO4 0.0046 g ZnCl2 0.0003 g ZnCl2 0.0003 mg

Co(NO3)2 0.0029 g CoCl2 0.0001 g CoCl2 0.0001 mg

FeCl3 0.0332 g MnCl2 0.0206 g MnCl2 0.0192 mg

ZnCl2 0.0017 g Na2MoO4 0.0024 g Na2MoO4 0.0023 mg

CoCl2 0.0007 g

MnCl2 0.0175 g

Na2MoO4 0.0139 g

INVENTORY ANALYSIS

Inputs and outputs


Goal and scope

Inventory analysis


Conclusions


Goal and scope

Inventory analysis


Conclusions

Contents

ENVIRONMENTAL IMPACT ASSESSMENT

Selected methodology and impact categories

• Photochemical oxidants formation

POFP

• Human toxicity HTP

• Freshwater aquatic ecotoxicity

MEP

• Marine ecotoxicity MEP

• Terrestrial ecotoxicity TEP

• Abiotic depletion ADP

• Acidification AP

• Eutrophication EP

• Global warming GWP

• Ozone layer depletion ODP

Use of LCI results to quantify environmental potential impacts

Assignment of impact categories according to CML 2001 method


Characterization results

Impact category Unit Chemical

disinfection Ozone

sterilization

ADP kg Sb eq 13.6 13.6

AP kg SO2 eq 12.1 12.1

EP kg PO4-3

eq 1.90 1.88

GWP kg CO2 eq 1.86 1.86

ODP kg CFC-11 eq 0.130 0.129

HTP kg 1,4-DBeq 321 319

FEP kg 1,4-DBeq 261 259

MEP kg 1,4-DBeq 190 188

TEP kg 1,4-DBeq 0.088 0.087

POFP kg C2H4 eq 0.490 0.490

Functional unit = 800 g astaxanthin


Relative contribution per stage

0%

20%

40%

60%

80%

100%

ADP AP EP GWP ODP HTP FEP MEP TEP POFP

Rel

ativ

e co

ntr

ibu

tio

ns

Cleaning of the reactor Preparation of the culture medium

Cultivation Harvesting

Extraction

Cultivation stage ≈ 80% of impacts


Relative contribution per involved activity

0%

20%

40%

60%

80%

100%


Rel

ativ

e co

ntr

ibu

tio

ns

Water Chemicals Materials

Transport Electricity Waste treatment

Electricity >75% of impacts


Relative contribution of electricity requirements

Reactor lighting in growth stage 19.5%

Aeration in growth stage 2.4%

Agitation in growth stage 2.4%

Reactor lighting in stress stage 58.5%

Aeration in stress stage 2.4%

Agitation in stress stage 2.4% Spray drying 4.2%

Supercritical fluid extraction 8.0%


Improvement scenarios

How to reduce electricity consumption



Improvement alternatives

Annular PBR with sunlight

Flat-panel PBR with artificial

lighting

Flat-panel PBR with sunlight



Sc 1 (base case): annular PBR with artificial

light and 800 g astaxanthin produced.

Sc 2: annular PBR with sunlight and 400 g

astaxanthin produced.

Sc 3: flat-panel PBR with artificial light

and 800 g astaxanthin production.

Sc 4: flat-panel PBR with sunlight and

400 g astaxanthin produced.



0

20

40

60

80

100


Rel

ativ

e co

ntr

ibu

tio

n (

%)

Sc. 1: 2 annular, artificial Sc. 2: 2 annular, sunlight

Sc. 3: 2 flat-panel, artificial Sc. 4: 2 flat-panel sunlight

Reductions of impact in all

proposed scenarios,

ranging between 15-75%


Goal and scope

Inventory analysis


Conclusions


Goal and scope

Inventory analysis


Conclusions

Contents

Conclusions

Environmental performance of a pilot-scale

microalgal process for the production of

high value-added molecules was evaluated

with LCA methodology.

Electricity consumption was identified as the

main responsible for the total impacts in all

categories, especially due to lighting

requirements in the cultivation stage.

Conclusions

Other steps of the process chain, such as

production of chemicals for culture medium,

materials for equipment or air supply present

secondary contributions in all the assessed

impact categories.

Results suggest that significant improvements

may be achieved by the use of alternative reactor

configurations, thanks to the lower electricity

requirements of these options.

Sustainable Production of Biologically Active

Molecules of Marine Based Origin

FP 7 - KBBE-2010-4 Collaborative Project www.bammbo.eu

Acknowledgements

“La mer est tout! Elle couvre

les sept dixièmes du globe

terrestre. Son souffle est pur

et sain. C’est l’immense

désert où l’homme n’est

jamais seul, car il sent frémir

la vie à ses côtés”

(Vingt mille lieues sous les mers, 1870)

Sustainable pilot-scale production of carotenoid

compounds from the green microalga


Paula Pérez-López, Sara González-García, Edward McHugh, Daniel Walsh,

Patrick Murray, Siobhan Moane, Gumersindo Feijoo, Mª Teresa Moreira November 25,

2013

Haematococcus pluvialis - · PDF fileWith more than 70% of ... Haematococcus pluvialis Green...

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