America's reliance on foreign oil has raised economic and national security issues, and in turn the U.S. has been active in reducing its dependence on foreign oil to mitigate these issues. Also, the U.S. Navy has been instrumental in driving bio-fuel research and production by setting an ambitious goal to purchase 336M gallons of bio-fuel by 2020. The production of microalgae biomass is a promising field which may be able to meet these demands. The utilization of microalgae for the production of bio-fuel requires the implementation of efficient culturing processes to maximize production and reduce costs. Therefore, three discrete rate event simulation models were developed to analyze different scaling scenarios and determine total costs associated with each scenario. Three scaling scenarios were identified by this analysis and included a stepwise, volume batching and intense culturing process. A base case and potential best case were considered in which the culturing duration, lipid content and lipid induction period were adjusted. A what-if analysis was conducted which identified and reduced capital and operational costs contributing greatly to total costs. An NPV analysis was performed for each scenario to identify the risk associated with future cash flows. The research findings indicate that the intense culturing scaling scenario yielded the greatest model throughput and least total cost for both the base case and potential best case. However, this increased productivity and cost reduction were not significantly greater than the productivity generated by the stepwise scaling scenario, suggesting that the implementation of flat plate bio-reactors in the intense culturing process may be non-advantageous given the increased operational costs of these devices. The volume batching scenario yielded the greatest total cost L^-1 of microalgae bio-oil for both, indicating an inefficient process. The scaling scenarios of the base case and potential best case yielded negative NPV's while the stepwise and intense culturing scenarios of the what-if analysis generated positive NPV's. The base case is based on current technological advances, biological limitations and costs of microalgae production therefore, a negative NPV suggests that utilizing microalgae for bio-fuel production is not an economically feasible project at this time.

abstract: Over the past decade, there has been a revival in applied algal research and attempts at commercialization. However, the main limitation in algal commercialization is the process of cultivation, which is one of the main cost and energy burdens in producing biomass that is economically feasible for different products. There are several parameters that must be considered when growing algae, including the type of growth system and operating mode, preferred organism(s), and many other criteria that affect the process of algal cultivation. The purpose of this dissertation was to assess key variables that affect algal productivity and to improve outdoor algal cultivation procedures. The effect of reducing or eliminating aeration of algal cultures at night, in flat panel photobioreactors (panels), was investigated to assess the reduction of energy consumption at night. The lack of aeration at night resulted in anoxic conditions, which significantly reduced lipid accumulation and productivity, but did not affect log phase biomass productivity. In addition, the reduction in aeration resulted in lower pH values, which prevented ammonia volatility and toxicity. Raceways are operated at deeper cultivation depths, which limit culture density and light exposure. Experimentation was accomplished to determine the effects of decreasing cultivation depth, which resulted in increased lipid accumulation and lipid productivity, but did not significantly affect biomass productivity. A comparison of semi-continuous cultivation of algae in raceways and panels in side-by-side experiments showed that panels provided better temperature control and higher levels of mixing, which resulted in higher biomass productivity. In addition, sub-optimal morning temperatures in raceways compared to panels were a significant factor in reducing algae biomass productivity. The results from this research indicate that increasing lipid productivity and biomass productivity cannot be completed simultaneously. Therefore, the desired product will determine if lipid or biomass productivity is more crucial, which also dictates whether the system should be operated in batch mode to either allow lipid accumulation or in semi-continuous mode to allow high biomass productivity. This work is a critical step in improving algal cultivation by understanding key variables that limit biomass and lipid productivity. / Dissertation/Thesis / Doctoral Dissertation Civil and Environmental Engineering 2015