Efficient cultivation infrastructure and control systems for FPA-Photobioreactors
The microalgae Cultivation Infrastructure from Subitec is a successful combination of precision work, innovative technology and careful attention to detail. It comprises a robust, technologically advanced system. This system seamlessly integrates the nutrient preparation system (Media Preparation), the cleaning and sterilisation system (Cleaning Unit), the harvesting system (Harvesting Unit), and the advanced control system (Control Unit). Connected to the media distribution, the Cultivation Infrastructure enables an efficient and productive cultivation process.
Wide range of media preparation and advanced filtration
The Media Preparation System, also known as the nutrient preparation system, forms the essential foundation of the cultivation process. Significantly, it plays a pivotal role in formulating the nutrient mix vital for microalgal growth. Remarkably, this advanced system specifically caters to the distinct needs of various microalgae species. It precisely calibrates a blend of macronutrients, micronutrients, vitamins, and trace elements. Consequently, this method ensures the cultivation of exceptionally high-quality, nutrient-rich microalgae.
An integral element of the system is its cutting-edge filtration technology, which effectively fosters a sterile environment conducive to microalgae growth. Impressively, the system employs a comprehensive multi-stage filtration process. The initial primary filtration primarily targets larger particles, while the subsequent secondary and tertiary stages increasingly focus on finer impurities. This meticulous filtration process consistently maintains the nutrient mixture’s purity and steadfastly upholds the highest quality standards throughout the cultivation process.
Efficient and scalable microalgae harvesting technology
At the end of the cultivation, the harvest takes place. Thus, the Cultivation Infrastructure becomes a key element in the process chain. The Harvesting Unit and System are tasked with ensuring the algae are harvested when their nutrient density is optimal. Through precise control mechanisms, this system ensures the nutritional value and integrity of the microalgae throughout the harvesting process.
The Harvesting System not only meets the highest quality standards for the harvested product but also ensures its availability in the desired quantity. It efficiently processes both small and large microalgae quantities, suitable for diverse production scales from laboratory to large-scale commercial applications. Furthermore, Subitec’s Harvesting System aids the downstream process, be it through centrifugation, filtration, or flocculation, thanks to the biomass’s high quality and density.
Innovative system for cleaning and sterilisation
The Cleaning Unit, incorporating the Cleaning-In-Place (CIP) and Sterilisation-In-Place (SIP) system, forms a crucial part of Subitec’s Cultivation Infrastructure. It ensures cleanliness and sterility, affecting not just the photobioreactors but the entire cultivation environment.
Reducing contamination risks, prevalent in cultivation systems, is a key focus of this system. Its methodology relies on scientifically validated cleaning approaches, specifically tailored to eliminate all potential contaminants, be they organic or inorganic. Such meticulous cleaning keeps the cultivation infrastructure free from harmful substances and contaminants.
Post CIP process, the SIP system employs highly effective chemical sterilisation agents. This sterilisation process not only removes microorganisms but also contributes to creating an ideal growth environment for microalgae. By integrating both CIP and SIP, Subitec presents a comprehensive solution, ensuring the cultivation process’s integrity from beginning to end.
Monitoring & adjustment in the cultivation process
Playing a central role in maximising cultivation success, the modern control technology from Subitec combines a stationary control system with a remote access function. This enables not only constant monitoring but also rapid adaptation to changing conditions.
The stationary system, serving as the cultivation infrastructure’s heart, connects directly to all relevant process modules. It facilitates continuous monitoring and optimization of parameters like nutrient content, temperature, and light intensity.
Moreover, the remote access control system allows operators to monitor the cultivation process in real time from afar and adjust as necessary. Secure VPN connections ensure the protection of both the cultivation process and its associated data at all times.
Innovative add-ons for improved productivity
Resource optimisation and environmental responsibility are becoming increasingly important. To this end, three innovative add-ons complement the CM180 Modules:
CO2-Recovery Unit
The recovery unit under development is not just about capturing carbon dioxide, but a strategic step towards sustainable production. By recycling and returning the CO2 to the process, the unit will not only conserve resources but also minimise the system’s carbon footprint, paving the way for environmentally friendly operations.
Water Recovery Unit
This unit, which is currently under development, will make an important contribution to water conservation in production. It will serve to recover and purify water from the production process and will ensure a smaller water footprint. The unit will thus make a decisive contribution to sustainable and resource-saving action.
Hydrogen Extraction Unit
An upcoming innovative add on that will use the potential of microalgae to produce hydrogen: The environmentally friendly energy carrier will be produced directly in the system by microalgae and can be extracted by the Hydrogen Unit. The industrial production system will thus offer an additional source of income and contribute to the energy transition.