Kona Demonstration Facility (KDF) - Cellana’s algal demonstration biorefinery

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Name
Kona Demonstration Facility (KFD)
Company
Cellana
Location
Kona (Hawaii’s Big Island, USA)
Category
Demonstration
Status
Running
Platforms
Oil
Feedstock
Microalgae
Products
Biofuels (ReNewTM Fuel), omega-3 fatty acids (ReNewTM Omega-3) and feed (ReNewTM Feed)
Start-up
2009
Production capacity
15 tons of algae biomass since 2010 for testing and business development purposes (Reference 2, march 2015)

Figure 1. Aerial view of KDF (extracted from Reference 2)

GENERAL INFORMATION

Cellana is a Hawaii-founded company focused on developing algae-based biofuels and bioproducts (feed, cosmetics, industrial chemicals and other valuable products) and reducing industrial emissions of CO2. It intends to construct and operate commercial algae-based biorefineries to achieve these goals.

Since 2009, Cellana operates its KDF on Hawaii’s Big Island. It is a 2.5 ha site (1,600 m2 under roof and 1 ha of cultivation systems) in Kona with approximately 1 Ml of cultivation capacity. KDF is designed to execute and support all stages of the production process at demonstration scale.

CULTIVATION TECHNOLOGY

At KDF, algae are cultivated in Cellana’s proprietary hybrid system (ALDUO™ technology covered by US Patents 7,770,322 & 5,541,056) using a combination of photobioreactors (25,000 L) and open seawater ponds (60,000 L). Photobioreactors (PBRs) ensure continuous production of biomass with maximum cell division and low contamination risk (nutrient replete stage). Biomass from PBRs are inoculated to open raceway ponds for generation of intracellular lipids over 3-4 day pond cycle (nutrient deplete stage). Oil accumulation in algae typically occurs during periods of environmental stress, including growth under nutrient-deficient conditions. In the open-pond growth phase, a nutrient-deficient environment is created in order to maximize oil production.

Figure 2. Photobioreactors (left) and open raceway ponds (right) at KDF (extracted from Reference 3)

Cellana’s technology optimizes the conditions for cultivation to improve efficiency using optimal turbulence in the water and the effective use of selected nutrients. All fluid transfers related to KDF cultivation and harvesting processes are operated and monitored by a remote process-control system.

BIOREFINERY MODEL

Algae are fully harvested when nutrient deplete through gravitational settling (5-8% solids content). Centrifugation (15-20% solids content) and drying (95% solids content) are subsequently used to reduce the water content. After harvesting and cell disruption, two streams are obtained: algal oil and residual biomass.

The biorefinery business model of Cellana is based on three products obtained through refining the two aforementioned streams:
  • ReNewTM FuelBulk oil for biofuel applications. As algae oil is comprised of triglycerides and fatty acids, there are a number of conversion technologies that can be used to convert it into biofuels, including transesterification and hydrotreating.
  • ReNewTM Omega-3: High value oils for human nutrition such as the polyunsaturated fatty acids DHA and EPA (omega-3 fatty acids) sold either as nutraceuticals, pharmaceuticals or feed/food additives.
  • ReNewTM Feed: The residual defatted biomass and carbohydrates can be used to make a fishmeal replacement or animal feed supplement for the aquaculture and animal feed markets.


Figure 3. Cellana’s algal biorefinery model (extracted from Reference 4)
_____________________________________________________________________________
REFERENCES
1 www.cellana.com (accessed on 7th May 2016).
2 D. Anton: “Advancing Commercialization of Algal Biofuels through Increased Biomass Productivity and Technical Integration” (Presentation). DOE BETO 2015 Project Peer Review, Algae Platform Review, March 25, 2015.
3 V. Harmon: “As Easy as “ABC” -- Always Be Commercializing: Cellana’s Multiproduct, BiorefineryBased Business Model: Today, Tomorrow and in the Future” (Presentation). Algae Biomass Summit, September 29 – October 2, 2014, San Diego.
4 J. Obbard: “Cellana” (Presentation). Hawaiʻi Pacific University and Oceanic Institute, 2011.
5 X. Bai, E. Knurek, N. Goes, L. Griswold: “Algal Lipids and Omega-3 Production via Autotrophic and Heterotrophic Pathways at Cellana's Kona Demonstration Facility, Hawaii” (Poster). Algae Biomass Summit 2012, Denver.

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