Semi-Industrial Algae Photobioreactor

In response to these objectives, scientists and academics from Plymouth Marine Laboratory (PML), University College London and Protein Technologies were interested in developing micro-algae, which could then be converted into raw materials for pharmaceutical, nutraceutical and cosmetic industry use.

PML and Protein Technologies therefore required the unique Design & Build of a semi-industrial scale photobioreactor. First of its kind, the photobioreactor needed to be modular in design, with integrated feed tanks, control and monitoring systems.

Our Solution

The project delivery strategy included the design and build of fully tested, preassembled and prewired photobioreactor units, which would be mounted on a skid frame to enable ease of transport and deployment in diverse applications across the world.

Our process engineering teams performed detailed process design calculations based on the physical and chemical parameters for growing microalgae. This ensured optimised conditions could be achieved within the photobioreactor, promoting algal growth.

Deviating from the conventional, coiled photobioreactor construction, we developed a straight, single tube photobioreactor. This original and innovative design provided better flow control access to each of the individual growth tubes, making it more robust and resilient than a conventional photobioreactor.

Following approval by the academic partners, we prepared 3D visualisations and fabrication drawings for manufacturing at our off-site prefabrication facility in Knowlsey, Liverpool.

Benefits to the Client

Groundbreaking research capabilities
The project boasts an understanding of the processes involved with producing sustainable materials, increasing awareness of UK research and demonstrating the application of such research into the manufacturing of commercial products.

Longevity through forward thinking
The 500 litre photobioreactor is the largest in Europe, producing one kilo (dry weight) of algal product. The unique modular design also means that the photobioreactor can be increased, to accommodate even larger scale growth runs, potentially up to industrial scale.

Client experience as a priority
The quality of the design ensures quick and easy clean down between experimental runs, improving usability.