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Review and experimental study on pyrolysis and hydrothermal liquefaction


of microalgae for biofuel production

Article  in  Applied Energy · January 2016


DOI: 10.1016/j.apenergy.2015.12.001

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Applied Energy 185 (2017) 963–972

Contents lists available at ScienceDirect

Applied Energy
journal homepage: www.elsevier.com/locate/apenergy

Review and experimental study on pyrolysis and hydrothermal


liquefaction of microalgae for biofuel production
David Chiaramonti a,⇑, Matteo Prussi a, Marco Buffi a, Andrea Maria Rizzo a, Luigi Pari b
a
Renewable Energy COnsortium for R&D, RE-CORD c/o Department of Industrial Engineering, School of Engineering, University of Florence, Viale Morgagni 40, I-50134 Florence, Italy
b
Consiglio per la Ricerca in Agricoltura e l’Analisi dell’Economia Agraria, Unità di Ricerca per l’Ingegneria Agraria, Rome, Italy

h i g h l i g h t s

 A review of microalgae thermochemical conversion to bioliquids was carried out.


 We focused on pyrolysis and hydrothermal liquefaction for biocrude/biofuels.
 Original experimental research on microalgae pyrolysis was also carried out.
 Starvation does not impact significant on the energy content of the biocrude.
 This result is relevant for designing full scale microalgae production plants.

a r t i c l e i n f o a b s t r a c t

Article history: Advanced Biofuels steadily developed during recent year, with several highly innovative processes and
Received 16 June 2015 technologies explored at various scales: among these, lignocellulosic ethanol and CTO (Crude Tall Oil)-
Received in revised form 29 November 2015 biofuel technologies already achieved early-commercial status, while hydrotreating of vegetable oils is
Accepted 4 December 2015
today fully commercial, with almost 3.5 Mt/y installed capacity worldwide. In this context, microalgae
Available online 19 January 2016
grown in salt-water and arid areas represent a promising sustainable chain for advanced biofuel produc-
tion but, at the same time, they also represent a considerable challenge. Processing microalgae in an eco-
Keywords:
nomic way into a viable and sustainable liquid biofuel (a low-cost mass-product) is not trivial. So far, the
Microalgae
Downstream processes
most studied microalgae-based biofuel chain is composed by microorganism cultivation, lipid accumula-
Hydrothermal liquefaction tion, oil extraction, co-product valorization, and algae oil conversion through conventional esterification
Pyrolysis into Fatty Acids Methyl Esters (FAME), i.e. Biodiesel, or Hydrotreated Esters and Fatty Acids (HEFA), the
Biofuels latter representing a very high quality drop-in biofuel (suitable either for road transport or for aviation).
Bioliquids However, extracting the algae oil at low cost and industrial scale is not yet a mature process, and there is
not yet industrial production of algae-biofuel from these two lipid-based chains. Another option can
however be considered: processing the algae through dedicated thermochemical reactors into advanced
biofuels, thus approaching the downstream processing of algae in a completely different way than sep-
aration. The present work examines the possible routes for thermochemical conversion of microalgae
into liquid biofuels, distinguishing between dry-processes (namely Pyrolysis, PO) and wet-processes
(near critical-water HydroThermal Liquefaction, HTL). A literature review on algae-HTL was carried
out, distinguishing between batch and continuous experiments, and compared to original results from
algae pyrolysis. In particular, pyrolysis was carried out on both starved (lipid-accumulated) and non-
starved microalgae. Typical composition of major products is given for both PO and HTL, comparing
the main characteristic of the products.
Major engineering advantages and challenges in thermochemical conversion of algae into liquid biofu-
els were identified and discussed for both processes, in view of the production of a transport biofuel and
the full exploitation of this renewable feedstock in energy and biorefinery complexes.
Ó 2015 Elsevier Ltd. All rights reserved.

⇑ Corresponding author.
E-mail address: david.chiaramonti@re-cord.org (D. Chiaramonti).

http://dx.doi.org/10.1016/j.apenergy.2015.12.001
0306-2619/Ó 2015 Elsevier Ltd. All rights reserved.
964 D. Chiaramonti et al. / Applied Energy 185 (2017) 963–972

1. Introduction and scope of work While carbohydrates are interesting for ethanol production, so
far the lipid production for biodiesel has attracted the greatest
A large number of scientific works demonstrated that the pro- interest: the potential oil yield per unit of used land of microalgae
duction of biofuels from microalgae is technically feasible [1], even is 5–20 times higher that of palm oil (ton ha1 yr1) [12,13].
if not yet optimized: however, the achievement of a positive eco- In a lipid-based approach toward diesel-like biofuels, as biodie-
nomical and energy balance is still under demonstration [2–4]. sel and HVO (Hydrotreated Vegetable Oils), specific cultivation
Today, as well as probably in the short/medium-term, biofuels techniques – such as Nitrogen and Phosphorous starvation can
from microalgae represent a niche area, with few existing commer- improve the oil quantity and quality toward downstream pro-
cial applications in non-energy sectors: nutraceuticals/functional cesses. In fact, depending on microalgae strain, removing nutrients
foods, feed supplements, aquaculture, pigments, and polyunsatu- (such as Nitrogen) from the growth medium reduces the cell divi-
rated fatty acids, diagnostic and fine chemicals. Micro-algae mar- sion process, generating a ‘‘stress” effect that increase cell size and
ket volume in 2004 was estimated equal to 5000 tons dry weight accumulate lipids, as observed in Chlorella vulgaris [14] and
per year, accounting for 1 Bill.€ economic value [5] (i.e. 200 €/kg Nannochloropsis sp. Bondioli [15] showed that oil from starved
dry alga in average). Clearly, the conversion of algae to sustainable Nannochloropsis sp. F&M-M24 has suitable characteristics for bio-
biofuels has not yet reached commercial level, despite the large diesel production: algae accumulated neutral lipids up to 50% of
potential offered by the algal feedstock. Among the main factors the dry biomass, with triglycerides representing the most
limiting the development of algae markets, especially biofuels abundant component. This algal oil – with the exception of a PUFA
and food, the most relevant ones are probably the biomass produc- – mostly fulfills chemical requirements for a feedstock to be
tion and processing costs, mostly due to the complexity of the cul- converted into biodiesel. However, lipids contained in microalgae
tivation phase and the downstream processes required to extract are located intracellular: this makes the oil extraction significantly
the high-value products in a biorefinery concept. Despite these more complex than the extraction from conventional oil seeds,
critical issues, and the actual light conversion (photosynthetic) such as sunflower or rape. In fact, mechanical pressing is not
efficiency, algae biofuels are particularly attractive thanks to the applicable to microalgae [16]. After harvesting, the algae paste still
following major elements: (i) algae can be produced on marginal contains more than 80% water (on wet basis): this is a key element
or degraded lands, avoiding competition with traditional food for the selection of the following downstream processing methods.
crops; (ii) algae are able to accumulate significant amounts of Wet extraction can thus be adopted in order to avoid biomass dry-
lipids (for biodiesel, HVO, and other processes) or carbohydrates ing and therefore save energy, improving the overall sustainability
(for bioethanol); (iii) algae can be grown without pesticides or her- [17].
bicides; (iv) algae can grow in saline waters, thus without deplet- However, dry extraction routes are today the more mature
ing fresh water resources; (v) algae can use carbon from flue gases; technologically options: moreover, they separate the protein-rich
(vi) they can be cultivated on wastewaters, where algae can also cake, a high added value co-products that contribute to improve
find part of those nutrients needed to grow [6]. the economic performances of the system. Chemical solvent
The development of an efficient microalgae-biofuel production extraction is the most common methods used to extract lipids from
pathway is still a major challenge toward commercial deployment, oily seeds: the efficiency of the solvent extraction process is
both from a strictly technical point of view as well as from an eco- strongly dependent on the specific algae strain under consideration
nomic one. Despite the high biomass production of microalgae per [18].
unit of land (t ha1), energy consumption of biofuels from algae – Wet extraction has the important advantage of avoiding the
including harvesting and extraction – is a major limiting factor drying step. In wet pathways, cell disruption can be based on
for the economics balance and overall sustainability. The algae har- mechanical approaches (e.g., microwave, ultrasonication, high
vesting phase is responsible for a significant share of energy con- pressure stresses, sudden changes of pressure, etc.), biological
sumption and it can account for a 20–30% of the total production approaches (e.g., use of enzyme for cell disruption, osmotic stres-
cost [7]. Downstream processing must separate very small cells ses, etc.) or thermochemical processing (e.g. Hydro Thermal
(1–50 lm) from a cultivation medium characterized by a very Liquefaction).
low density of microorganisms (from 0.5 to 3 gr l1). Moreover, Among the biological extraction methods, enzymatic extraction
there is no optimal solution for algae harvesting and downstream degrades the cell wall, with relevant energy saving [19]. In fact,
processing, as each algae strain and product destination can set dif- even if cell membranes of several microalgae (such as Chlorella)
ferent technical specifications [8–10]. In fact, physical shape, cell have very resistant layers, these can be degraded by the action of
wall structure, and microorganism composition can show signifi- a proper mixture of enzymes [20]. The advantages offered by the
cant variations even considering the same strain cultivated follow- enzymatic route are the mild reaction conditions and the high
ing just two different procedures. The selection of the harvesting selectivity: compared with mechanical methods, enzymatic meth-
method for a certain strain should be carried out taking into ods thus exhibit very competitive performances [21]. The critical
account the specific downstream process. As various authors agree, element of this method is represented by the enzyme cost.
also the dewatering phase should be evaluated on the base of the Hydrotreating can be economically competitive only if imple-
following thermochemical treatment, so to achieve a proper oper- mented at large scale. Efforts have been done even to retrofit exist-
ation and reducing overall energy consumptions [7,11]. ing refineries to HVO, with a first installation entered in operation
The approach to downstream processing of microalgae toward in Porto Marghera, Venice.
biofuels and bio products can be very different. We can identify Once the oil is extracted from the cells, the most diffused route
two major possible pathways: toward biofuels is the transesterification process, which generates
biodiesel, a mixture of Fatty Acid Methyl Esters (FAME). Biodiesel,
 Microalgae are pre-processed, extracting the high added value which consists of ‘‘oxygenated” components, can be blended with
compounds as lipids and/or carbohydrates, and then biofuels fossil fuels only up to a certain percentage, and therefore subject to
and biochemical are produced from the different fractions. the so called ‘‘blend wall” (7% v/v in the EU). Actually, biodiesel exhi-
 The entire microorganisms are processed in the cultivation bit several limitations, such as low oxidation stability, poor charac-
medium (wet processing), and bioliquids or intermediates are teristic at low temperatures, and it becomes a solvent at higher
produced. blends. A way to overcome these limits, and to produce a very high
D. Chiaramonti et al. / Applied Energy 185 (2017) 963–972 965

quality diesel-like biofuel from lipid-feedstock is represented by the extracted in the form of suitable raw materials for biofuels without
hydrotreatment of triglycerides. Hydroprocessing of vegetable oils/ solvents by pyrolysis. Wang et al. [31] compared direct and indirect
lipids consist of hydrogenation of the double bonds existing in the oil pyrolysis of microalga Isochrysis. They concluded that defatted
chains and the removal of Oxygen (through decarboxylation/decar microalgae pyrolysis represents a potential way to convert protein
bonylation and hydrodeoxygenation, that produces straight chain and carbohydrate to biofuels, even if the increase of N-heterocyclic
paraffins), followed by catalytic selective hydrocracking/isomeriza- compounds and phenols and a decrease for hydrocarbons were
tion and separation of the different hydrocarbon cuts. This process observed. Zhao et al. [32] examined the effect of co-pyrolysis of
leads to a product consisting in a mixture of C15–C18 hydrocarbons, Isochrysis and Chlorella. There was no obvious difference in the
sometimes named as ‘‘green diesel”, ‘‘renewable diesel” or ‘‘bio- maximum biocrude yields for individual pyrolysis and co-
hydrogenated diesel”, fully compatible with fossil diesel [22]. Other pyrolysis, but carboxylic acids decreased and N-heterocyclic com-
lighter liquid and gaseous fractions from the process consist in pounds increased in co-pyrolysis.
hydrocarbons in the boiling point range of jet fuel or gasoline, and Studies also addressed the catalytic cand non-catalytic pyrolysis
propane [23,24]. Hydrotreating, as almost all biofuel technologies, of algae residues after lipid extraction. Murata et al. [33] investi-
requires large scale production facilities in order to be economically gated the use pyrolysis of Botryococcus (B.) Braunii residue after
competitive, such as those developed by Neste Oil (NEXBTL) and Botryococcus Braunii oil (Bot-oil) extraction. Using a Py-GC/MS sys-
ENI–UOP (Ecofining). Both new dedicated HVO installations (Neste tem coupled with H-ZSM-5 catalyst, they obtained 88.6% of hydro-
Oil) and retrofitting of existing refineries (ENI–UOP) have been real- carbon, a significantly higher amount compared to the 35.2%
ized in the last years in the EU and abroad. These systems already without catalyst. However, yields were in the range of 30%. Aysu
investigated the use of algal oil in the process. and Sanna [34] also analyzed catalytic (ceria-based) pyrolysis of
However, considering microalgae, and taking into account the microalgae Nannochloropsis in a fixed bed reactor. The presence
difficulties in extracting the lipids from the microorganisms, a pos- of the catalyst allowed for higher retention of the initial energy
sible alternative route is processing the whole algae stream. Ther- in the microalgae, as well as higher aliphatic and lower acids and
mochemical processes are available both on dry (pyrolysis) as well oxygen content, even if the highest bio-oil yield was slightly above
as on wet (hydrothermal liquefaction) phase: despite PO and HTL 23% at best. Francavilla et al. [35] carried out fast pyrolysis exper-
pathways have been largely investigated for lignocellulosic feed- iments on lipid-extracted microalga Dulaniella Tertiolecta, observ-
stock, processing algae presents different challenges than lignocel- ing that the quality of obtained bio-oil still requires upgrading,
lulosic biomass. namely deoxygenation and denitrogenation. Char was also
Rizzo et al. [25] already carried out a preliminary investigation obtained, but the surface area was almost negligible, thus hamper-
on the characterization of intermediate microalgae pyrolysis oil ing its potential use as sorbent.
from Chlorella and Nannochloropsis sp. at CREAR/RECORD facilities. As regards microalgae HTL, recently, Patel et al. [36] and Guo
This work highlighted that algae pyrolysis oil exhibited interesting et al. [37] carried out reviews on hydrothermal pretreatment of
properties as intermediate energy carrier, especially when com- microalgae and bio-oil production, identifying major achievements
pared to oil from fast pyrolysis of lignocellulosic biomass (e.g. pine and research needs. Yoo et al. [38] investigated the HTL of microal-
chips): lower Oxygen content – thus a higher HHV, H/C ratio closer gae versus the quality of the produced oil and the energy return on
to diesel, lower density and a mild basic pH. The same semi-batch investment. Their major finding was that high-lipid containing
pyrolysis reactor has been used to further investigate the conver- microorganisms are necessary to target transport fuels, and that
sion of algae biomass. increasing the process conditions toward higher severity (i.e.
Recently, a continuous and increasing amount of studies and higher temperature) will determine higher yields but lower quality
research works were carried out on the subject of thermal treat- liquids. Faeth et al. [39] previously demonstrated in a lab-scale
ment of microalgae. This growing interest reflects the number of batch reactor that biocrudes of similar quality may be produced
funded research projects and industrial initiatives that entered into in higher yields and in a fraction of the time previously thought
operations in the last year, and the biorefining approach that is necessary, with the positive effects on plant capital costs thanks
currently being promoted and combines high added value products from the reduced reactor volume.
with bioenergy components. Similarly to Wang et al. [31] for pyrolysis, Garcia Alba et al. [40]
Raheem et al. [26] recently carried out a literature review on previously suggested that HydroThermal Treatment (HTT) is most
microalgae processing through the thermochemical route to obtain suited as post-treatment technology in an algae biorefinery sys-
biofuels. They remarked how these studies indicate that microal- tem, after the wet extraction of high value products, such as
gae pyrolysis oils are more stable and less oxygenated than pyrol- protein-rich food/feed ingredients and lipids. Yang et al. [41]
ysis oils from lignocellulosic biomass. They also confirmed that the examined the behavior of low-lipid microalgae major components,
liquefaction of microalgae is a very promising pathway to produce namely crude polysaccharides, crude proteins and their binary
higher quality bio oils, with calorific value close to those of petro- mixtures, in HTL. The main outcome of the study was that while
leum oil. Previously, also Chen et al. [27] reviewed the thermo- polysaccharides provide only a small (less than 5%) contribution
chemical conversion of microalgae. Silva et al. [28] compared to bio-oil and more than 60% were distributed in the aqueous
different routes to microalgae biofuels, namely microalgae pro- phase as water soluble organics, proteins have a major role on
cessed by solvent ultrasound-assisted extraction followed by lipids bio-oil formation (maximum 16.29%). The higher energy recovery
transesterification, bio-oil from microalgae pyrolysis, and, slow was however observed from the mixture.
pyrolysis of lipid extraction leftovers. Carbon footprint of each Jazrawi et al. [42] and Roussis et al. [43] investigated two stage
chain as well as product quality were discussed, as N content. HTL, and and Costanzo et al. [44] recently compared this approach
López-González et al. [29] made an assessment of pyrolysis and versus single stage HTL in a lab-scale batch reactor, with the aim of
combustion of microalgae and their oils from the energetic, eco- reducing nitrogen content in biocrude, increasing the nutrient con-
nomic and environmental point of view, comparing Scenedesmus tent in the aqueous phase, and producing a biocrude that can be
sp. and N. gaditana. co-processed in conventional oil refineries thanks to its lower N
Na et al. [30] studied rapid pyrolysis (in Py-GC/MS) of oleaginous and O content. Costanzo et al. [44] concluded that, given the signif-
microalga, Chlorella sp. KR-1 with different triglyceride contents, icant reduction in biocrude yield observed for high protein algae,
confirming the role of triglycerides in the biofuel characteristics, the two-stage approach could be interesting for high-lipid content
and concluding that the triglycerides in the microalgae could be microalgae.
966 D. Chiaramonti et al. / Applied Energy 185 (2017) 963–972

An important element of hydrothermal liquefaction of microal- However, pyrolysis of algae feedstock present very different and
gae is represented by the water-phase, and its possibility of re-use peculiar characteristics compared to lignocellulosic biomass: these
in the algae cultivation system itself. Xu and Savage [45] investi- unique properties reflect in the pyrolysis product itself.
gated the water-soluble and water-insoluble fraction of HTL bio- Fig. 1 shows a possible general scheme coupling microalgae
crude from microalgae, demonstrating the effect of reaction time cultivation and pyrolysis process, while Fig. 2 describes a HTL-
and algae loading. The aqueous phase of biocrude was reduced based scheme. Following the cultivation stage, microalgae are
increasing reaction time, while the water-insoluble fraction separated and then extensively dried (as required by the pyrolysis
increased with reaction time. Similar but larger effects were process). Pyrolysis oil and char are the main products recovered
observed at higher algae loading. Hognon et al. [46] compared from the pyrolysis step, while the non-condensable gases can be
pyrolysis and HTL of Chlamydomonas reinhardtii, focusing on the used to provide heat to the thermochemical process as well as to
recovery of the aqueous medium for microalgae cultivation, a dry the algae paste. Exhaust gases, recovered from the combustion
key issue in industrial application of microalgae HTL. Pyrolysis of non-condensable, can be used to supply up to 10% w/w of the
and HTL showed opposite trend in bio-oil yield at increasing tem- CO2 needed by the microorganism during cultivation (without
perature, with pyrolysis improving from 400 °C to 550 °C and HTL considering CO2 distribution efficiencies). This scheme will process
reducing from 220 °C to 310 °C. Tests on re-use of aqueous phase the whole algae stream, i.e. the entire alga composed by carbohy-
for microalgae growth showed promising results, but they con- drates, proteins, lipids, and other remaining components as ash.
cluded that the high organic carbon content may be toxic, and thus An alternative route could be based on biomass fractionation
water need to be treated. just after the microalgae separation step. In this way, high added
The biocrude obtained from microalgae hydrothermal treat- value products can be recovered from the algae stream, and then
ment needs upgrading: among other, Wang et al. [47] recently the remaining biomass/co-product can be fed to the pyrolyzer,
addressed the upgrade of HTL oil through hydrogen treatment after drying.
from microalgae grown in wastewater, showing that it is possible Pyrolysis oil can be seen as an intermediate energy carrier, a
to improve in this way the quality of the biocrude. They also crude oil, or a chemical carrier, while the aqueous phase could be
observed that some liquid products and sulfur were deposited in recovered either through anaerobic digestion (AD), or sent to other
the spent catalysts. Some authors, as Yang et al. [48] also investi- agronomic uses. Excess charcoal (the solid coproduct of pyrolysis,
gated aviation biofuels from microalgae, concentrating on the car- used to provide heat to the process) could also be used as biochar
bon distribution and comparing different process routes. Pyrolysis in the soil [52].
and HTL lead to high bio-kerosene products. Scientific literature reports a significant number of experimen-
It is finally important to remark that most of the past research tal research works carried out on algae pyrolysis, confirming the
works addressed batch systems and autoclave experiments, while feasibility of pyrolysis oil production from microalgae [53–57].
hydrothermal treatment will necessarily be a continuous process Slow pyrolysis was investigated by Grierson et al. [58], that
in industrial installations. In this respect, a recent work by Elliott considered six different microalgae species: oil yields range
et al. [49] focused the attention on continuous-flow processing sys- between 24% and 43% w/w, with char yields ranging from 34% to
tems. In their review they elaborated process models and mass/ 63% w/w. Pan et al. [59] studied the influence of temperature
energy balances. However, they also observed that engineered sys- and catalysts on of Nannochloropsis sp. under slow pyrolysis condi-
tems so far did not yet achieved a demonstration scale: neverthe- tions. In their work the oil yield ranged from 19% w/w with
less, there is significant potential for commercialization of the catalyst to 31% w/w in presence of HZSM-5 catalysts. A further
technology. advantage of using a catalyst was the higher heating value of the
The present work focused on past selected works in the field of obtained liquid product (32.7 MJ kg1). However, being charcoal
thermochemical treatment of microalgae, specifically HTL, and the main product from biomass slow pyrolysis, the interest in
integrate these with original results from dedicated experimental using algae in combination with this process is today very
works of microalgae pyrolysis, investigating specifically selected marginal.
microorganism so to derive innovative conclusions on their energy Rizzo et al. [25] processed Chlorella sp. at 450 °C under interme-
conversion. diate pyrolysis conditions, obtaining a net yield of 34% w/w for liq-
uid and 29% w/w for char. Pyrolysis oil from Chlorella sp. showed
peculiar characteristics, being less oxygenated than lignocellulosic
2. Pyrolysis of algae PO (35 vs. 54% w/w), higher HHV (28.4 vs. 17.2 MJ kg1), lower
acidity (pH 9.2 vs. 2.3) and lower density (1 vs. 1.1–1.2 kg m3).
Pyrolysis is a thermochemical process which is normally carried Fast pyrolysis has also been investigated with the aim of maxi-
out at atmospheric pressure and temperature ranging from 300 to mizing the algae bio crude oil yield. Miao et al. [60,61] studied fast
700 °C and above, in complete absence of Oxygen. Main products of pyrolysis of several microalgae species, as Chlorella protohecoides
pyrolysis are a solid (char), an organic liquid (crude oil) and a low and Microcystis aeruginosa, obtaining oil yields ranging from
calorific value gas (pyrogas), in different ratios depending on pro- 17.5% w/w to 23.7% w/w.
cess conditions, reactor type and feedstock characteristics. Fast
and flash pyrolysis, characterized by high heating rate and short
vapor residence time, maximize liquid yield (pyrolysis oil, also 3. Algae HTL (hydrothermal liquefaction)
called bio-crude oil) when temperatures are in the range of
approximately 450–550 °C, with mass yield of the organic liquid Hydrothermal liquefaction (HTL) can directly convert wet bio-
typically between 50% and 70% w/w [50]. Fast pyrolysis oil from masses into liquid bio crude (or solid bio coal at less severe pres-
lignocellulosic biomass is an acidic and very complex liquid pro- sure–temperature conditions) either with or without the use of a
duct [51], easily subject to separation in different fractions. Feeding catalyst [62]: after initial investigations years ago, as reported in
a pyrolysis unit requires extensive drying of biomass at inlet, nec- recent review works [63,64], HTL gained again the attention of
essary to achieve high heating rates in the reactor and adequate the researchers in recent years [65], when processing wet feed-
temperature control, so to reduce phase separation during storage. stock such as micro or macro algae, lignin from lignocellulosic
Pyrolysis oil is generally seen as an intermediate energy/chemical ethanol production, organic wastes or other highly wet organic
carrier, suitable for further biorefining in downstream plants. feedstock has become a very up-to-date issue.
D. Chiaramonti et al. / Applied Energy 185 (2017) 963–972 967

Fig. 1. Scheme of possible microalgae–pyrolysis integrated process.

Fig. 2. Scheme of possible microalgae–HTL integrated process.

The thermochemical reaction take place on wet biomass in The typical HTL oil yield reported in several studies is equal to
water near critical conditions, i.e. process temperatures and pres- approximately 50–60% w/w [67], depending also on the use of
sures around 280–370 °C and 10–25 MPa (<2 MPa: HTC) [66]. homogeneous or heterogeneous catalysts. Minowa et al. [69] pub-
The HTL conversion efficiency of microalgae depends on various lished some results on hydrothermal liquefaction of microalgae (B.
parameters such as reaction temperature, residence time and feed- braunii and D. tertiolecta) in a batch reactor fed with high concen-
stock composition. Differently from the algae-to-biodiesel path- tration of algae: 50–78.4% w/w. At 300 °C the oil yield was between
way, which essentially depends on the microalgae strain and 37% w/w and 64% w/w depending on the type of algae processed.
lipid contents, HTL and pyrolysis can be used to convert not only More recent research works investigated C. vulgaris and Chlorella
the lipid fraction of microalgae, but also the other organic compo- pyrenoidosa, Nannochloropsis occulata, Scenedesmus dimorphus, Por-
nents such as proteins and carbohydrates [67], either as a whole or phyridium cruentum, Desmodesmus sp. as well as Chlorogloeopsis
separated. The chemical properties of biocrude oil are directly fritschii and Spirulina cyanobacteria. These works demonstrated
related to feedstock composition [44]. HTL oil contains approxi- that a wide range of microalgae can be processed in HTL reactors,
mately 10–20% w/w of Oxygen and Nitrogen, with energy density obtaining a mixture of Oxygenated hydrocarbons with a high mass
in the range of 30–37 MJ kg1 [68]. Hydrothermal liquefaction of yield [40,62,70,71]. Zou et al. [72] investigated HTL of microalgae,
microalgae thus appears to be a very interesting technology for combined with wastewater treatment, demonstrating that both
wet biomass processing and biofuel production, but not industri- low-lipid high-protein Nannochloropsis sp. (B) and high-lipid low-
ally yet developed [64], with few and small scale continuous reac- protein Chlorella sp. (Y) can be efficiently converted to biocrude
tor used for testing. oil. The observed highest yields were 55.0% and 82.9% respectively.
968 D. Chiaramonti et al. / Applied Energy 185 (2017) 963–972

The hydrocarbon content in biocrude was in the range of 6.7–29.8% The test procedure starts with reactor heating under a constant
for Nannochloropsis sp. and 4.7–17.9% for Chlorella sp. Elliott et al. Nitrogen flow of 4 l min1; the Nitrogen is injected by means of a
[66] achieved high conversions yields even at high algae concen- serpentine pipe coiled along the body of the reactor, so to maintain
trations, up to 35% w/w of dry solids. Elliott et al. effectively the inlet Nitrogen temperature close to the reactor one. A mass of
applied catalytic hydrotreating for hydride oxygenation, hydroden- 10 kg of metal spheres of 22 mm diameter are to the reactor and
itrogenation, and hydrodesulfurization of the biocrude. An impor- stirred by paddles, so to increase the biomass heating rate. Then,
tant result of this study was that catalytic hydrothermal as the system achieves steady conditions, the feedstock is fed in
gasification can be effectively applied for HTL bio-product water batches of 20–40 g. Before loading the biomass into the reactor,
clean-up, in order to allow nutrients recycle in algae growth ponds. the material is flushed for 30 s with Nitrogen. The rotational speed
From an industrial and economic point of view, continuous of the shaft driving the paddles in the reactor (fixed at 15 rpm) is
reactors are most likely needed for process scale-up, but several controlled by an inverter. The PID control then regulates the power
technological challenges still have to be addressed. Continuous supplied to the resistors to keep the process temperature constant
reactors are fed at low concentration of solid (algae), in order to during biomass thermochemical conversion. Once the material is
avoid various technical problems as component plugging, deposi- completely processed, paddle stirring is stopped and solid dis-
tions, etc. Jazrawi et al. [73] investigated Chlorella and Spirulina charge port opened, to un-load the reactor from solid residue
with a loading factor between 1 and 10% w/w biomass, at 250– (char). Solids (char) are collected in a closed vessel purged with
350 °C, for 3–5 min residence time and 150–200 bar. The maxi- Nitrogen, and then cooled down to room temperature before being
mum biocrude yield was 41.7% w/w. opened for material collection.
Most significant elements for the development of microalgae
HTL processes are related to the feeding stage, especially in terms
of aggregation state and load concentration, temperature, resi- 4.2. Analytical methods
dence time, use of catalysts, product separation and water
recirculation. Analyses on feedstock and bio-oils were carried out at the RE-
CORD chemical laboratory in Scarperia (Italy), and unless differ-
ently specified, all determinations were carried out in triplicates.
4. Material and methods The content in Carbon, Hydrogen, Nitrogen and Sulfur (CHN + S)
was determined through a Leco TruSpec for Carbon, Hydrogen and
4.1. Pyrolysis unit Nitrogen and a TruSpec Add-On Module for Sulfur according to an
internal lab method. Water content was measured according to
A 1.5 kg h1 semi-continuous intermediate pyrolysis pilot unit UNI EN ISO 8534, that specifies a method for the determination
was designed and built at CREAR/RE-CORD-University of Florence. of the water content of animal and vegetable fats and oils using
The reactor consists of a cylindrical body made of corrosion resis- Karl Fischer apparatus and a reagent which is free of pyridine.
tant stainless steel (AISI 310) externally heated by ceramic-shell Ash content was determined with a Leco TGA 701 according to
electrical resistors, able to heat and maintain the oxygen-free UNI EN 14775 by heating up to 550 °C and holding there for at least
nitrogen-blown reactive chamber up to 600 °C. Feedstock mixing 2 h 30 min. Ash content of pyrolysis products was measured by
is promoted by paddles connected to a variable speed shaft. The heating the sample up to 750 °C and holding there for at least
reactor presents three openings: one for biomass loading, a second 1 h 30 min.
one for continuous extraction of pyrolysis vapors, and the last one Higher heating value (HHV) was measured according to UNI EN
for discontinuous, manually operated, solid residue removal. 14918 for solid samples, or DIN 51900-2 for liquid samples, by
Vapors are cooled by a series of condensers. The mixture of non- means of a Leco AC500 isoperibol calorimeter. The lower heating
condensable gases are vented outside by an ATEX-certified blower. value (LHV) was calculated according to UNI EN 14918, Sections
A PID (proportional–integral–derivative) controller regulates pro- 4.2 and 12.2. This value was derived from the HHV, providing that
cess temperature; data acquisition is performed continuously. A the total hydrogen content of the moisture-free sample can be
scheme of the pilot unit is reported in Fig. 3. determined by experiment (i.e. CHN analysis).

Fig. 3. Scheme of the semi-continuos pyrolysis reactor [74].


D. Chiaramonti et al. / Applied Energy 185 (2017) 963–972 969

Density of liquids was measured at 20 °C by means of a cali-


brated glass hydrometer according to UNI EN ISO 3675.
Kinematic viscosity of pyrolysis liquids were measured accord-
ing to UNI EN ISO 3104 with a Lauda viscometer made by an Ubbe-
lohde capillary (k = 0.3) at several temperature between 20 and
60 °C. Each measurement was carried out at the selected tempera-
ture for five times: two times in order to precondition the capillary
tube, then the last three times for analyses: an interval of 90 s was
allowed between each measurement.
Acid value (TAN) was determined according to UNI EN 14104,
where the sample is dissolved into a solvent mixture and titrated
with a dilute solution of potassium hydroxide using phenolph-
thalein as indicator.

4.3. Mass yield, energy and carbon recovery

Bio-oil mass yield, carbon recovery and energy recovery were


calculated and compared for each tested feedstock.
Oil mass yield is calculated according to Eq. (1). Oil mass yield
(mass yield) is defined as the ratio of the recovered bio-oil
(mbio-oil), either as a whole or considering the water- and organic-
rich fractions collected, to the mass of feedstock (mfeed).
mbio-oil Fig. 4. Fine powder algae sample.
mass yield ¼ ð1Þ
mfeed
The energy recovery in the products was calculated according to Table 2
the following Eq. (2). Energy recovery (ER) is the ratio between HHV Algae processed and PO yield (centrifugation@2500 rpm, 20 min).
of the products (HHVbio-oil) multiplied by the products amount, on
Parameter Unit of measurement A B
the HHV of the feedstock (HHVfeed) multiplied by the feedstock
Processed biomass grdb 685 420
amount:
Raw oil yield gr 305 170
Raw oil yield % w/w 44.5 40.5
HHVbio-oil  mbio-oil
ER ¼ ð2Þ Water phase yield gr 54 20
HHVfeed  mfeed Organic phase yield gr 251 150
Organic phase yield % w/w 36.6 35.7

5. Experimental results
The total amount of algal biomass fed to the pyrolysis reactor is
5.1. Characterization of microalgae reported in Table 2 with the oil yield, and water/organic phases of
this.
Two microalgae samples were analyzed and then fed to the Both oils were composed by two phases: a water rich phase and
intermediate pyrolysis pilot unit. Both samples were originated an organic one. The amount of the organic phase for both batches,
from the same strain of Nannochloropsis sp. F&M-M24, but culti- after 20 min of centrifugation at 2500 RPM, was equal to approxi-
vated according to two different protocols, either aimed to maxi- mately 36% w/w of the initial biomass. Oil main characteristics are
mize the protein (case A) or the lipid content (case B) through presented in Table 3.
Nitrogen starvation. Table 1 reports the chemical characteristics These two pyrolysis oils mostly show similar characteristics:
of the two feedstock on a dry base. however, they are considerably different from lignocellulosic bio-
As expected, the most relevant difference between the two mass pyrolysis oils or vegetable oils. While viscosity of algal PO
samples relates to the Nitrogen content. In fact, sample A had is comparable to lignocellulosic pyrolysis oils [25], pH (close to
7.8% w/w Nitrogen (representing a total protein content of about 7) represents a major difference from lignocellulosic biomass
47%wt) and only 23% w/w of total lipids, while sample B had
3.8%wt Nitrogen content and a total lipid content of the
45% w/w. Fig. 4 shows the algae aggregation state. Table 3
Characterization of pyrolysis oil from microalgae samples A and B.

Parameter A B Unit of Norm


Table 1 measurement
Elemental analysis of tested microalgae samples. Kinematic 30.9 31.8 mm2/s UNI EN ISO 3104
viscosity@40 °C
Parameter A B Unit of measurement Norm
pH 7.25 8.12 – –
Ashes 10.9 14.3 % w/wdb UNI 14775 Water content 19.4 16.7 % w/w UNI EN ISO 8534
C 52.1 53.9 % w/wdb UNI 15104 Higher heating value 29.3 28.2 MJ/kg DIN 51900-2
H 7.2 7.5 % w/wdb UNI 15104 Lower heating value 26.9 26.1 MJ/kg DIN 51900-2
N 7.8 3.8 % w/wdb UNI 15104 S 0.19 0.3 % w/w Internal method
S 0.7 0.6 % w/wdb UNI EN 15289 C 58.8 52.1 % w/w ASTM D 5291
O 21.3 19.6 % w/wdb Calc. by difference H 10.6 10.2 % w/w ASTM D 5291
Higher heating value 25.8 25.5 MJ/kgdb UNI 14918 N 4.0 5.8 % w/w ASTM D 5291
Lower heating value 24.3 23.9 MJ/kgdb UNI 14918 O 26.4 31.6 % w/w Calc. by
difference
db = dry basis
970 D. Chiaramonti et al. / Applied Energy 185 (2017) 963–972

Table 4 5.2 Pyrolysis and HTL process comparison


Balance of energy conversion.

Parameter Unit of measurement A B When comparing microalgae pyrolysis and HTL, some critical
Processed biomass gr 605 420 issues for the pyrolysis step can be highlighted. Drying represents
Biomass HHV MJ/kg db 25.8 25.5 a major critical point from a system perspective for pyrolysis: this
Energy input (in biomass) MJ 15.6 10.7 is particularly relevant for microalgae due to their extremely low
Pyrolysis oil yield gr 251 150 concentration in the cultivation medium (typically ranging from
Pyrolysis oil HHV MJ/kg 28.2 29.3
Pyrolysis oil energy output MJ 7.1 4.4
10% to 20% even after harvesting and some pre- concentration
% of Energy yield in oil % 45.6 41.1 stage).
Table 5 reports a comparison among major physical and chem-
ical characteristics of algae pyrolysis oil, algae HTL oil, lignocellu-
losic HTL oil, vegetable oil and diesel oil: HTL appears as a very
pyrolysis oil (around 2–3), having significant impact on materials interesting and promising option.
for reactor and plant construction as well as systems for oil use. Based on literature review, experimental analysis and product
Also the water content, even if slightly below lignocellulosic oil, characterization, some useful indications toward engineering of
still requires dewatering during upgrading: also the amount of algae PO and HTL processes can be derived.
Oxygen and Nitrogen is considerable, and need reduction. The pos- As regards pyrolysis, the peculiarity of the algal feedstock intro-
sibility of using catalytic (hydro)treatments to remove Oxygen and duces unique and critical key points for the design of the reactor
Nitrogen in pyrolysis oil from microalgae C. vulgaris has already itself as well as the entire system. The pyrolysis reactors used for
been demonstrated by various authors, including López Barreiro these preliminary tests and in similar experiments available in liter-
et al. [64] in a recent work. Interestingly, despite Oxygen, Nitrogen ature (excluding the batch reactors, not relevant for these consider-
and water content, the heating value of microalgae pyrolysis oil is ations) are essentially still those used with lignocellulosic biomass:
equivalent to approx 2/3 of the diesel oil and similar to other however, algae clearly have very different characteristics, such as
widely diffused biofuels (as bioethanol). composition (mainly carbohydrates, proteins and lipids), high inor-
Mass and energy balances of the process carried out at lab/pilot ganic and ashes content, peculiar state of aggregation depending on
scale are reported in Table 4: clearly, given the pilot scale of the the harvesting and pretreatment (fine powder or fluffy material). It
experimental facilities, the process is not optimized and/or is certainly necessary to develop a reactor specifically designed for
energy-integrated, and thus results could be largely further microalgae, so to optimize the feeding system, the heating methods,
improved. the reactor design, and the overall performances. Also innovative
The mass balance for the total oil collected, already given in integration of plant components is needed, as low temperature heat
Table 2, is almost 36% w/w. The result is even more relevant in streams from the pilot unit could be effectively used for algae dry-
terms of energy yield: in fact, while the primary energy input ing, thus achieving significant energy optimization not yet in place
(algae) is equal to 15.6 MJ for sample A, the energy yield is today.
7.1 MJ, corresponding to an energy conversion rate of approxi- HTL offers the immediate advantage of processing wet feed-
mately 46%. The same data for sample B are slightly lower, around stock and determining a less oxygenated biocrude, thus more
41%. appropriate for upgrading into biofuels. Continuous HTL unit will
Another major results of these results is related to the effect of operate at lower algae concentration than batch system, but are
the process on two microorganisms (feedstock) that either are necessary to design industrial scale concepts. However, the high
lipid-rich (starved culture) or carbohydrate/protein rich: in terms nitrogen content will require adequate hydrodenitrogenation
of energy yield, no significant differences were observed in stages, while the use of salty water for algae cultivation will
pyrolyzing the two samples. In other terms, the collected data indi- require careful design and evaluation of possible corrosion-
cate that, at least at this stage, no energy-yield advantages are pre- related problem. In addition, deposition of inorganic is expected
sent in increasing the lipid content of the algae, expecially if it near critical conditions: these will have to be removed from the
generates a reduction in the algae plant productivity. liquid stream in order to allow its re-use in the system after the

Table 5
Comparison among pyrolysis, HTL and vegetable oils.

Parameter Pyrolysis oil Pyrolysis oil HTL lignocell. HTL algae (biocrude) HTL algae (aqueous) Vegetable oil from Diesel Unit of
algae A algae B [75] [64,76,77] [64,66,77] sunflowera EN590 measurement
Kinematic 31.8 30.9 >300 110–350 1–2 26.0 2–4.5 mm2/s
viscosity@40 °C
pH 8.12 7.25 – – 7.5–7.8 n.a n.a. –
TAN – – 30–60 2–8 – 1.06 n.a. mgKOH/g
Density – – 0.82–1 0.94–0.96 1–1.05 0.91 0.84 kg/dm3
Water content 16.7 19.4 3–13 2–8 95–96 0.085 <0.02 % w/w
HHV 28.2 29.3 30–35 35.4 Negligible 39.48 42–43b MJ/kg
LHV 26.1 26.9 n.a. n.a. Negligible 36.97 44–45b MJ/kg
S 0.3 0.19 n.a. 0.3–0.5 – 0.002 <0.001 % w/w
C 52.1 58.8 67–80 77–80 1.8–3.7 77.8 87b % w/w
H 10.2 10.6 6–8 10 11–12 11.9 13b % w/w
N 5.8 4 0–2 4 0.5–1.1 0.01 – % w/w
O 31.6 26.4 11–23 5–8 84–85 10.3 – % w/w
COD – – – – 60,000–125,000 – – mg/kg
a
Reference norm DIN 51605.
b
Typical.
D. Chiaramonti et al. / Applied Energy 185 (2017) 963–972 971

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