The Consortium of ProfiKomp® Environmental Technologies Inc. and HDH-Engineer Ltd. successfully closed their project entitled ‘Technological development of microalgae culturing systems using 3D printed modular units with unique geometry’ (Project No: 2018-1.1.2-KFI-2018-00131) on 30 November 2020.

Beneficiary: Consortium led by ProfiKomp® Environmental Technologies Inc. Consortium partner: HDH-Engineer Ltd. Project title: Technological development of microalgae culturing systems using 3D printed modular units with unique geometry Project No: 2018-1.1.2-KFI-2018-00131 Amount of support: HUF 485,612,824 Proportion of support: 69.99% Period of implementation: 01/12/2018 – 30/11/2020

The Consortium of ProfiKomp® Environmental Technologies Inc. and HDH-Engineer Ltd. successfully closed their project entitled ‘Technological development of microalgae culturing systems using 3D printed modular units with unique geometry’ (Project No: 2018-1.1.2-KFI-2018-00131) on 30 November 2020.

The total eligible cost of the project launched on 1 December 2018 and implemented within 24 months amounted to HUF 693,818,320, of which the amount of support received was HUF 485,612.824.

The main objective of the research project was to use microalgae in the field of biotechnologies for reducing carbon dioxide (CO₂). During the implementation phase, a device that may be used to produce large amounts of algae biomass on a small area and within a short period was designed and constructed. This is the so-called photobioreactor (PBR), which was essentially designed to be a closed system. Due to its closed nature, CO₂ circulating in the photobioreactor cannot easily escape from the system. It was also an important consideration that the photobioreactor should have a large specific surface area (ensured by a design made of pipes and spirals) so microorganisms can use solar energy for carbon sequestration in the most efficient way. During the development of the PBR, our consortium partner, HDH Engineer Ltd., contributed to our work during the design process. They applied 3D printing technology to the construction of specific fixtures of the structure. Additive manufacturing enabled the rapid production of those pieces that were either unavailable for commercial use, or needed to be slightly modified.

Our technological solution involves a two-circuit system for the reduction of CO₂ emissions. In the first round, CO₂ content is discharged from flue gases and biogas. For this process, two scrubbing devices were designed and constructed during the period of research: one with a “bubble” structure, and another with a packing design. Of the two designs, the latter proved to be more efficient. These units required several specific components, including the diffusor responsible for producing the smallest possible size of bubbles, the sprinkler for vaporizing the liquid, or the unordered packing ensuring the largest possible film surface.

The dewatering process is one of the main obstacles to microalgae biotechnologies becoming widespread. As only several grams of dry biomass can be produced from 1 litre of suspension –- however, on a weekly basis if needed – separating alga from water is an issue of strategic importance. For this purpose, two additional units were designed and developed: (1) a piece of sedimentation equipment by which the majority of biomass can be separated from water, and (2) a piece of dryer equipment using solar energy that can dewater the algal cells that are still jellied and wet.

During product development, the most important issue was energy efficiency. The incorporation of passive fixture also serves this purpose; with the use of these elements, gravity and solar energy can be utilized to the highest possible degree during the operation of the equipment.  A significant reduction in the environmental impact can be achieved with the use of this innovative technology. For this reason, the nutrient supply of the algae is partially ensured by the growth media, made from the wet extract of agricultural by-products, while a carbon supply is ensured by carbon dioxide discharged from flue gases. Identifying the methodology for facilitating the above-described processes was an important part of the research, as well as examining the further agricultural utilization of biomass for soil-improving or yield-enhancing purposes.

One output of the research project is the prototype of a marketable product family, developed in association with a service package related to their application. The technology thus developed can be easily scaled to different plant sizes.