BionicCellFactory

Algae grow best at a CO₂ concentration of around two percent. However, since our ambient air contains far less than one percent, the CO₂ collection module enriches the algae with a higher concentration: it filters the required gas from compressed air by introducing it into a chamber which has CO₂-binding granulate blown into it.

The granulate consist of a polymer that, depending on the prevailing conditions, can absorb CO₂and also release it. When the granulate has absorbed sufficient CO₂it is heated to a temperature of 90 degrees Celsius to release the gas again. The concentrated CO₂is finally cooled in an intermediate storage tank and blown into the bioreactor via a gassing element.

A major challenge with bioreactors is to accurately determine the amount of biomass. For this purpose, we use an optical method based on microscopy and AI, as well as quantum technology, in the analysis module. The digital microscope continuously delivers images that are evaluated by the AI. Through training images, it has learned to recognize the algae cells.

For the quantum-based particle sensor, a precision pump transports the algae cells out of the cultivation system. Using a precise valve system, they are fed to a mixing tank where they are diluted with water for optimal analysis conditions. The pressure-over-liquid principle enables a uniform flow velocity and directs the mixture to the quantum sensor.

The sensor – developed by start-up Q.ANT – provides huge amounts of data, which can consist of the size and number of algae, as well as foreign bodies. These analyses make it possible to react to process events in advance and to intervene in a regulating manner.

The heart of the BionicCellFactory is a 45-meter-long tube system from Algoliner with a capacity of 80 liters. In this transparent, illuminated photo section, the algae cells photosynthesize under optimal growth conditions. Sensors continuously measure conductivity, pH, oxygen and CO₂ concentration as well as the temperature.

The system adds nutrients such as potassium, phosphorus and nitrogen depending on the needs of the algae. A heat exchanger ensures the correct temperature control. Mass flow control and innovative piezo valve technology enable precise metering of air. Up to 20 liters per minute are supplied via an aeration element. The resulting fine air bubbles ensure the optimum exchange of CO₂and O₂between algae and the environment.

The Harvest module is the interface between cultivation and enzymatic transformation of the biologically grown material. A centrifuge ensures continuous harvesting of the biomass: at a speed of 10,000 rpm, the algae cells are separated from their aqueous environment and forced to the edge; the water is returned to the process.

Via a pump, the algae are finally transferred to the next module for further processing. The timing and amount of harvesting are regulated to keep the algae vitality at the optimal level and provide the appropriate amount of biomass for transformation in the next step.

Five so-called transformation cubes with individual tasks create optimal conditions for the refinement of algae by enzymes. They are biological catalysts that are fed in a targeted manner. Thus, they support the gradual transformation, which does not require any heavy metals.

In order to finally extract individual components from the harvested algae, so-called enzyme shears cut open the cell walls and thus access the ingredients: starch, proteins, colorants, and the algae oil that we wanted in our case. Hardly any energy is required for this, because the environmentally friendly process runs at mild – automatically controlled – ambient conditions of 40 degrees Celsius and a pH value of five. The algae oil obtained can now be used as a food supplement and for the production of cosmetics, or further processed into energy sources or bioplastics. The algae residues can be used as feed or fertilizer.