Performing Department
(N/A)
Non Technical Summary
The goal of this project is to continue the success of our Phase I proof-of-concept work by implementing a full-scale, algal-based treatment system to remove nutrients (such as nitrogen and phosphorus) from wastewater in small rural communities and to produce a pelletized, slow-release algal fertilizer as a value-added byproduct.Problem/Opportunity:Nutrient pollution in our nation's waterways is a major issue. These nutrients, which stem mainly from municipalities and agriculture, are causing environmental problems such as fish kills and toxic cyanobacteria blooms. To address this issue, state and federal agencies are enforcing stricter nutrient discharge limits for municipalities. These regulations result in a growing need for improved technologies such as our algal system (especially in rural communities). Furthermore, the current methods for generating fertilizer are not sustainable and are energy-intensive. New biobased fertilizer options are desired, and the algal-based fertilizer developed in this project addresses that need.Project Objectives:This Phase II SBIR is designed to produce and collect the remaining data needed to prove to our customers (rural communities) and their professional advisers that our process is reliable, cost-effective, and environmentally friendly. The major objectives of this project are to (1) build and evaluate a full-scale algal treatment system, (2) determine the best method to process algae into a saleable pelletized fertilizer, (3) evaluate the algae fertilizer in plant-growth studies, and (4) conduct an economic and life-cycle analysis of our proprietary algal treatment to fertilizer process. Following this Phase II project, our process will be ready for commercial deployment.
Animal Health Component
80%
Research Effort Categories
Basic
10%
Applied
80%
Developmental
10%
Goals / Objectives
Objective 1: Design, construct, and startup a full-scale RAB treatment system: We will design, install, start-up, and debug the RAB system at full-scale. We anticipate identifying unforeseen challenges related to building and operating a RAB system. Key information for designing, manufacturing, and installing the RAB system will be gained. This objective will be critical to identify accurate costs for manufacturing and installing the RAB system at full-scale, thereby providing us with the information needed to develop an accurate cost structure for selling the RAB system.Objective 2: Monitor the performance of a full-scale RAB system over a 12-month period: We will evaluate the efficiency and capacity of a full-scale RAB system. This system will be located at a municipal treatment lagoon in Dallas Center, IA. During this 12-month evaluation, important pollutant removal parameters will be determined. Removal performance will be evaluated throughout the year against changing environmental parameters due to seasonality. The impact of infiltration and inflow (I&I) on treatment capacity will also be determined. Biomass productivity will be evaluated during this year period. The major outcome of this objective will be full-year operational data that can be used to demonstrate the efficiency, capacity, costs, and reliability of the RAB system to regulatory agencies and our customers.Objective 3: Development of a saleable algal fertilizer product: We will convert the algae grown on wastewater into a storable, transportable, and easy to apply slow-release fertilizer pellet. Since the algae produced will be generated from raw municipal wastewater, it will be considered a biosolid that must be stabilized before being sold. We will evaluate approved biosolid stabilization methods to treat algal biomass and determine the most economical method. Different drying methods will be evaluated for moisture removal from the algal biomass to determine the most efficient method. Low-value, dry biochar will also be blended with algae to reduce or eliminate the need for drying prior to pelletization. The stabilized, dried, and pelletized material will be evaluated for desirable fertility parameters such as N, P, K content and undesirable parameters such as toxic metals and pathogens. The major outcome for this objective is to identify the most energy-efficient, cost-effective, and high-throughput method to process the wastewater-grown algae into a saleable fertilizer product.Objective 4: Perform a plant growth trial using pelletized algae fertilizer: The pelletized algal fertilizers generated in objective 3 will be tested in a plant growth trial. A pure algae pellet and an algae-biochar blend pellet will be evaluated. These fertilizers will be evaluated against COTS synthetic and organic fertilizers. Marigold, tomato, and turf grass will be used to test the fertilizers. These trials will take place at Iowa State University (ISU). The algal fertilizers will be considered successful if they attain equal/better plant growth results compared to the COTS fertilizers.Objective 5: Evaluate the economics and environmental impact of the RAB treatment process coupled with slow-release fertilizer production: The entire water treatment-to-algal fertilizer process will be evaluated. Throughout objectives 1-4, important parameters relating to treatment capacity, fertilizer efficiency, costs and environmental impact will be gathered. These values will be put into an economic model to determine the complete capital and operating costs for this process. Furthermore, the environmental impact parameters identified will be used to determine energy consumption, CO2 sequestration, and greenhouse gas emissions. The major outcome of this objective will be to provide our customers the treatment capacity, fertilizer efficiency, cost structure, and environmental impact required for a full-scale RAB-to-fertilizer process.
Project Methods
Objective 1: Design, construct and startup a full-scale RAB systemObjective 1, Task 1: Manufacture and Evaluate One RAB Module:The initial design work for the full-scale RAB system will be completed prior to this Phase II project commencement. Once this project starts, one RAB module (Figure 6A) will be built. This RAB module will be evaluated by GWT and Doerfer staff to determine if there are design improvements that must be made prior to manufacturing the remaining 21 modules. When evaluating the RAB unit, it will be stress tested to validate motor size, bearing durability, and structural integrity of the frame. During this test, we will run the system under full load for two weeks and then take it apart to identify faulty parts. The reactor will be reassembled and this process will be repeated until the reactor has no faulty parts and no more improvements are identified.Objective 1, Task 2: Install and Start Up the Full-scale RAB SystemDuring the installation and startup period, each aspect of the process will be carefully tested and evaluated. All parts will be evaluated for functional operation, durability, and ease of maintenance. The costs associated with all hardware and installation will be documented. The deliverables at the end of this objective will be: (1) determine accurate manufacturing and installation costs for a full-scale RAB system installation and (2) a functional full-scale RAB system that can be evaluated in objective 2 (12-month evaluation of RAB system performance).Objective 2: Monitor the performance of a full-scale RAB system over a 12-month periodWe will evaluate the efficiency and capacity of a full-scale RAB system. This system will be located at a municipal treatment lagoon in Dallas Center, IA. Important treatment pollutant removal parameters will be determined during this 12-month evaluation. These parameters include removal capacities and efficiencies for ammonia, nitrate, total N, total P, and COD. These will be evaluated throughout the year against the changing environmental parameters due to seasonality. The impact of I&I, which is caused by rainwater entering wastewater sewers, on treatment capacity will also be determined. The biomass productivity will be evaluated during this 12-month period.Objective 3: Development of a saleable algal fertilizer productWe will convert the algae grown on wastewater into a storable, transportable, and easy to apply slow-release fertilizer pellet. Since the algae produced will be generated from raw municipal wastewater, it will be considered a biosolid, and may contain pathogens, it must be stabilized before being sold. In this objective, we will evaluate the use of different approved biosolid stabilization methods to treat algal biomass and determine the most economical one. Different drying methods will also be evaluated to remove moisture from the algal biomass to determine the most efficient one. Low-value, dry biochar will be blended with the algae to decrease the need for drying. Following processing, the pellets will be evaluated for desirable fertility parameters such as N, P, and K content as well as undesirable parameters such as toxic metals and pathogens.Objective 4: Perform a plant growth trial using pelletized algae fertilizerThe pelletized algal fertilizer generated in objective 3 will be used in plant growth trials in this objective. The algae-based fertilizers to be evaluated are pure algae pellet and algae-biochar blend pellet. These fertilizers will be evaluated against COTS synthetic and organic fertilizers, and a control with no fertilizer addition. The plants that will be tested are marigold, tomato, and turf grass. These trials will take place at an ISU research plot.Objective 5: Evaluate the economics and environmental impact of the RAB treatment process coupled with slow-release fertilizer productionIn this objective, the entire water treatment-to-algal fertilizer process will be evaluated. During objectives 1-4 data about wastewater treatment capacity, pellet processing, costs, and environmental impact will be collected. These values will be put into an economic model to determine the capital and operating costs associated with this process. Also, the environmental impact parameters that are identified will be used to determine energy consumption, CO2 sequestration, and greenhouse gas (GHG) emissions.