System and method for continuous fermentation of algae

Abstract

The present invention is a method for fermentation of algae or algaefaction method. The method includes feeding a hydrocarbon composition into a gasifier and pre-heating a biomass stream from a fermentation reactor. The biomass stream includes a liquid portion, a catalyst, and a biomass solids portion ranging between 15-92% by weight ofthe biomass stream. The biomass solids portion is algae or algal solids. The biomass stream is pre-heated to a temperature range between 200° F. and 500° F. Both the syngas and the pre-heated biomass stream are injected as a mixture into a reactor, where the mixture is separated into a gas component, liquid component, and solids component. The solids component is algal crude, which can be collected for processing as transportation fuels. The gas component is a lower temperature syngas, which can also be collected for processing as electricity or transportation fuels.

1 . A method for fermentation of algae, said method comprising the steps of:
 feeding a hydrocarbon composition into a gasifier, said gasifier converting said hydrocarbon composition into a syngas of a temperature range between 300° F. and 1500° F., said syngas being comprised of carbon monoxide, hydrogen and impurities;   pre-heating a biomass stream, being comprised of a liquid portion, a catalyst, and a biomass solids portion ranging between 15-92% by weight of said biomass stream, said biomass solids portion being algal solids, said biomass stream being pre-heated to a temperature range between 200° F. and 500° F.;   injecting said syngas and the pre-heated biomass stream as a mixture into a reactor;   separating the mixture into a gas component, liquid component, and solids component, said solids component being algal crude, said gas component being a lower temperature syngas, said step of separating comprising:
 heating said syngas and the pre-heated biomass stream to a temperature greater than 600° F., 
 dissolving said syngas into said liquid portion of the biomass stream in said reactor; 
 defusing said syngas into cellular structure of the biomass stream for a predetermined amount of time; and 
 flashing the defused biomass stream mixture to change phase from liquid to vapor within said biomass cellular structure; 
   collecting said lower temperature syngas;   cycling said solids component to pre-heat said biomass stream, the solids component being cooled in order to pre-heat said biomass stream; and   collecting the cooled solids component.   
   
   
       2 . The method of  claim 1 , further comprising:
 recycling a portion of the solids component as said hydrocarbon composition into said gasifier.   
   
   
       3 . The method of  claim 1 , the step of injecting having the mixture under pressures between 500 and 2000 psig in said reactor. 
   
   
       4 . The method of  claim 1 , the step of heating in the step of separating the components having the mixture at a temperature of 1400° F. 
   
   
       5 . The method of  claim 1 , the step of flashing in the step of separating the components being a pressure release in less than 0.5 sec, bursting algal cell structures. 
   
   
       6 . The method of  claim 1 , further comprising:
 transferring said biomass stream from a fermentation reactor.   
   
   
       7 . A system for fermentation of algae according the method of  claim 1 , the system comprising:
 a gasifier means for converting a hydrocarbon composition into a syngas of a temperature range between 300° F. and 1500° F., said syngas being comprised of carbon monoxide, hydrogen and impurities;   a pre-heating means for heating a biomass stream, said biomass stream being comprised of a liquid portion, a catalyst, and a biomass solids portion ranging between 15-92% by weight of said biomass stream, said biomass solids portion being algal solids, said biomass stream being pre-heated to a temperature range between 200° F. and 500° F.;   a means for injecting said syngas and the pre-heated biomass stream as a mixture into a reactor;   a means for separating the mixture into a gas component, liquid component, and solids component, said solids component being algal crude, said gas component being a lower temperature syngas, the separating means comprising:
 a reactor housing said syngas and the pre-heated biomass stream at a temperature greater than 600° F., said syngas being dissolved into said liquid portion of the biomass stream in said reactor and defused into cellular structure of the biomass stream for a predetermined amount of time; and 
 a flash chamber, changing the defused biomass stream mixture from liquid to vapor within said biomass cellular structure; 
   collecting means for the lower temperature syngas;   a means for cycling said solids component to the pre-heating means, the solids component being cooled in order to pre-heat said biomass stream; and   a means for collecting the cooled solids component.   
   
   
       8 . The system of  claim 7 , further comprising:
 a means for recycling a portion of the solids component as said hydrocarbon composition into said gasifier.   
   
   
       9 . The system of  claim 7 , the mixture being pressurized between 500 and 2000 psig in said reactor. 
   
   
       10 . The system of  claim 7 , the reactor housing the mixture at a temperature of 1400° F. 
   
   
       11 . The system  claim 7 , the defused biomass stream mixture being de-pressurized in said flash chamber in less than 0.5 sec, bursting algal cell structures. 
   
   
       12 . A system for fermentation using algae comprising:
 a fermentation reactor having a first reactor section and a second reactor section, said first reactor section being a continuous stirred tank reactor, said second reactor section being a plug flow reactor, a first baffle separating said first reactor section and said second reactor section and being movable within the fermentation reactor, said fermentation reactor producing a biomass stream having algae;   a gasifier means for converting a hydrocarbon composition into a syngas of a temperature range between 300° F. and 1500° F., said syngas being comprised of carbon monoxide, hydrogen and impurities;   a pre-heating means for heating said biomass stream, said biomass stream being comprised of a liquid portion, a catalyst, and a biomass solids portion ranging between 15-92% by weight of said biomass stream, said biomass solids portion being algal solids, said biomass stream being pre-heated to a temperature range between 200° F. and 500° F.;   a means for injecting said syngas and the pre-heated biomass stream as a mixture into a reactor;   a means for separating the mixture into a gas component, liquid component, and solids component, said solids component being algal crude, said gas component being a lower temperature syngas, the separating means comprising:
 a reactor housing said syngas and the pre-heated biomass stream at a temperature greater than 600° F., said syngas being dissolved into said liquid portion of the biomass stream in said reactor and defused into cellular structure of the biomass stream for a predetermined amount of time; and 
 a flash chamber, changing the defused biomass stream mixture from liquid to vapor within said biomass cellular structure; 
   collecting means for the lower temperature syngas;   a means for cycling said solids component to the pre-heating means, the solids component being cooled in order to pre-heat said biomass stream; and   a means for collecting the cooled solids component.   
   
   
       13 . The system according to  claim 12 , further comprising:
 a dewatering means for removing water from the biomass product from the fermentation reactor, being in fluid communication with said second reactor section;   
   
   
       14 . The system according to  claim 12 , wherein said first reactor section having a second baffle that can be varied in size or shape so as to optimize the fermentation reaction within the first reactor section. 
   
   
       15 . The system according to  claim 12 , wherein said first baffle having a first reactor position and a second reactor position, said second reactor position providing a residence time of up to seven days. 
   
   
       16 . The system according to  claim 12 , wherein said first reactor section having an inlet and an outlet, said second reactor section having an inlet and outlet, said inlet of said second reactor section being in fluid communication with said outlet of said first reactor section, said first reactor section having a second baffle separating said first reactor section, said second reactor section being movable and having an opening therein, said opening coinciding with said outlet of said first reactor section and said inlet of said second reactor section. 
   
   
       17 . The system according to  claim 12 , wherein said first baffle being moveable within said first reactor section, said first reactor section and said second reactor section have adjustable volumes. 
   
   
       18 . The system according to  claim 12 , wherein said second reactor section being impervious to light.