Algae and the scale dilemma or how to transform a ‘curiosity’ into an industry

picture-11 The biofuel sector finds itself in a bind, pummeled by the economic crisis and a shortage of funding.   Also of concern, is ethanol’s poor environmental record.  Nonetheless, algae continues to be seen as a promising feedstock that could revive the once promising biofuel industry. On paper, algae is attractive: it does not require large tracts of land to grow, and it is not a food crop, unlike corn or other sugar-based feedstocks that can tighten regional food supplies. Plus, it’s a carbon sink, because it requires large amounts of CO2 to grow.

Los Angeles-based OriginOil is one of a growing number of research and development companies that have been working to develop a scalable and commercially viable algae production model.

GER recently caught up with OriginOil CEO Riggs Eckelberry, who provided an overview of the opportunities and challenges faced by this budding sector as it seeks to scale from a curiosity into a viable industry.

Eckelberry says OriginOil could roll out an industrial application within the next five years. One such application could be a biodiesel refining production line. A full-fledged industrial production for the sector as a whole could take longer — at least 10 to 15 years, according to industry advocates. Eckelberry agrees, noting that the launch of vast power plant-sized centralized production plants will take even longer to develop. He compares the current state of play in the algae industry to the early days of the Internet, when for each Amazon there were hundreds of ambitious startups with fresh ideas and a lot of cash to burn but with no clear commercial strategy. “There’s a lot of smoke out there,” he warns.

There are many potential algae startups vying to lead this nascent industry. There are also many useful applications for algae-based fuels. The most obvious is as a gasoline replacement for automobiles. A blend of algae-based jet fuel is also being developed to power large airplanes. The U.S. Air Force is considering pumping algae-based fuel into some of its jets, and Greenwire reports that plant-derived fuels, including algae, could fill the tanks of some commercial flights as early as next year.
Converting the entire mass of algae (oil and biomass) to liquid fuel could generate about 500 liters (132 gallons) of diesel distillate from a metric ton of algae biomass. “That is a very rough number,” notes Eckelberry. Also, in theory at least, the carbon released by burning the algae-based biofuel is re-captured to feed new algae, making the whole process carbon-neutral. Finally, a byproduct of the process is biomass that can be used to produce methane to power large electric generators at the biofuel processing facilities.
While algae offers multiple marketable outlets, producing the stuff remains complex and expensive, costing 10 to 30 times more than traditional biofuels such as corn-based ethanol or soy-based diesel. The entire production process of algae-based fuel is full of challenges, which OriginOil — and its competitors — are working to resolve.

OriginOil has developed what it calls a ‘Single-Step Extraction‘ process that it says can extract oil from thick algae cells and separate the algae oil from the water and its biomass, all in a single step. The process works in the lab now; the question is whether it can be scaled into a commercial application.

OriginOil's Single-Step Extraction process

Diagram of OriginOil's "Single-Step Extraction" process

“Going commercial” is tricky for any venture. The reality is that most startups fail to do so. In the algae sector, GreenFuel Technologies, once one of the best funded companies, was forced to pull the plug last month, falling victim to the credit crunch and the poor economy. The company, underscoring the true complexity of algae production, was also saddled with technical issues, the major one being that it was never able to fully control the algal growth.

OriginOil hopes to avoid the same fate with its Single-Step Extraction technology. The process is at the core of the company’s identity and development plan. “We’re a technology company,” Eckelberry often repeats. That’s a short way to say that the company has no intention of becoming a fully integrated “algae major,” able to produce, refine and market its green fuel. It instead would like anyone in the business of oil to buy its technology. As such, the model for OriginOil seems more Microsoft and less Chevron.

Over the next few years, OriginOil plans to continue to improve its algae technologies. The company’s cash burn rate averages about $200,000 a month, mostly to support its R&D effort.

Eckelberry says algae “logically is the end game for biofuel.” The challenge now, he says, is to scale up production. “We need to show that we can do it. [Algae] has to move away from being a curiosity and become a viable industrial product.”

One Response to “Algae and the scale dilemma or how to transform a ‘curiosity’ into an industry”

  1. Andy says:

    Interesting piece, Terry! That makes me more optimistic that algae-derived energy might be feasible.

    Andy

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