WO2021141554A1 - Spherical mechatronic autonomous photobioreactor - Google Patents

Abstract

This invention is related to a spherical autonomous photobioreactor which is used in such fields as space researches, and Bio-Fuel, Bio-Fertilizer, Pigment and Bio-Plastics production, and pharmaceutical and cosmetic industries, chemical industry, medicine and genetics, and can effect full environment-controlled natural environment simulation under seasonal sun control and controlled natural/artificial lighting conditions by using renewable energy sources for production of photosynthetic / aphotosynthetic monocellular or multicellular organisms, or production of biosimilar living organisms (algae, diatoms, etc.) or biosimilar tissues.

Description

SPHERICAL MECHATRONIC AUTONOMOUS PHOTOBIOREACTOR TECHNICAL FIELD

This invention is related to a spherical autonomous photobioreactor which is used in such fields as space researches, and Bio-Fuel, Bio-Fertilizer, Pigment and Bio- Plastics production, and pharmaceutical and cosmetic industries, chemical industry, medicine and genetics, and can effect full environment-controlled natural environment simulation under seasonal sun control and controlled natural/artificial lighting conditions by using renewable energy sources for production of photosynthetic / aphotosynthetic monocellular or multicellular organisms, or production of biosimilar living organisms (algae, diatoms, etc.) or biosimilar tissues.

PRIOR ART

There are 6 existing and known techniques¹ usable for production of photosynthetic / aphotosynthetic monocellular or multicellular organisms, or production of biosimilar living organisms:

A) Circular stirred pond

B) Channel type (raceway) pond

C) Horizontal or perpendicular tubular photobioreactor D) Air-lift reactor

E) Spiral tubular photobioreactor

F) Flat plate or BigBag type (Bagged) photobioreactor

In this field, Algae account for the most comprehensive production methods. However, others are also produced by the same types of systems. Cultivation of microalgae in outdoor ponds for this production has been started in 1950s. The

¹ Cited and further developed from an article titled “Mikroalg iiretimi ve mikroalglerden biyoyakit eldesi” (Production of microalgae and deriving bio-fuel out of microalgae) of Ph. D. Harun Elcik and Prof. Dr. Mehmet Cakmakci published in pages 795-820 of issue 3 of 32nd volume of Gazi University, Journal of Faculty of Engineering and Architecture, in 2017. method most commonly used in microalga cultivation is channel-type (raceway) ponds for large-scale systems. Channel-type ponds are comprised of oval-shaped closed-cycle recirculation channels. Their depth is between 0.2 and 0.5 meters, and their width is approximately 0.25 meters. In channel-type ponds, precipitation of organisms is prevented by means of a continuously operating blade wheel. Blade wheel also ensures circulation of algae and food stuffs. Production efficiency of channel-type ponds is lower than that of tank photobioreactors due to some environmental factors. Given that it is exposed to atmosphere, water is lost through evaporation, and ion concentration of culture medium increases to cause harm to growth of organisms. Furthermore, it can be easily contaminated by other microorganisms preventing growth of organisms. Daily and seasonal changes of temperature and sunlight may also effect the production, In addition, reduction of CO2 transfer speed by increasing culture intensity also drops the production efficiency.

Tank photobioreactors have been designed in order to eliminate disadvantages of outdoor pond systems. However, their installation, operation and renewal costs are fairly above those of outdoor ponds. Tank photobioreactors have different types such as tubular, flat plate, rectangular and continuous stirring.

Tubular photobioreactors are most commonly used tank bioreactors. Tubular photobioreactors are comprised of transparent tubes made from glass or plastic materials. Depending on the design of tubes, they have perpendicular, horizontal, spiral and inclined types. Diameter of tubes is generally 0.1 m or less as it effects contact of light on intensive culture medium. In tubular photobioreactor, culture of organisms circulates between feed magazine and reactor with the help of a pump. Thus, blending of food stuffs in culture medium is ensured, and gas transfer increases, and precipitation of organisms is minimized. However, due to clinging tendency of organisms, their clinging on surface and seaming points inside tube cannot be fully prevented. Therefore, exchange of species cannot be made without use of heavy cleaning chemicals or without replacement of tube. What’s more, after some time, internal surface loses its transparency due to flow, and all of the tubes are required to be replaced. Flat-plate (FP) or BigBag type (Bagged) photobioreactors are among the oldest types of tank systems. FP photobioreactors have high biomass intensity due to their large surface areas in contact with light. They are manufactured of transparent material in order to increase the contact of light source with reactor. Air is fed to the system for blending operation. Photosynthetic efficiency of FP reactors is high. Reactors are cost-efficient, and easy to manufacture and procure. Flowever, it is difficult to control their temperature and CO2 circulation rate due to their large surface area. Furthermore, organisms tend to stick on surface. That is why cleaning becomes a problem. They cannot be used in large scale. FP photobioreactors do not require any stirring apparatus, differently from tubular reactors, because stirring is affected by means of a gas distribution system fitted at the bottom part of reactor. Continuous stirred tank reactors are systems with low contamination risk which can be used outdoors or indoors. Mechanical stirrer and light source are fitted at the top part of reactor. Discharge channel and gas injector are at the bottom part of reactor. Flowever, its cleaning is rather difficult due to its narrow and deep area of usage. Their internal surfaces are required to be renewed due to flow-caused friction. In BigBag (Bagged) types, though it is said that bags are for several uses, in general, they cause a separate cost at each time because of perforation, puncture or adhesion.

Air-lift (AL) photobioreactors are simple and cheap reactors used in production of a great many types of microalgae. They are generally manufactured of cheap and easy-to-procure plexiglass materials. Air-lift reactor is equipped by a flow column constituting the perpendicular circulation flow therein. Diameter of bioreactors is generally between 0.15 and 0.40 meters. Risk of contamination is low in AL photobioreactors.

Compared to open and outdoor systems, photobioreactors ensuring water, chemical and energy savings are said to be more appropriate and fit for biomass production. However, there are some problems in industrial-scale use of highly efficient laboratory-scale photobioreactors. Production efficiency of biomass may fall down due to increase of reactor volume and dimensions for industrial applications. Table 1 shows a comparison of these production systems.

Table 1: Comparison of different microalgae production systems

In the application with a publication number of W02017002084A1 , the system is created as a combination of raceway pool and perpendicular tubular systems. A microalga inoculation equipment wherein pond paddle provides circulation by combination of infinite tubular-pool channels is mentioned to be used for circulation in a liquid growth medium. It contains a second integrated gas release system corresponding to a perpendicular photobioreactor column each installed and fitted with intervals along the length of channel, as well as a structure causing circulation of CO2 by feeding the same to growth medium. At the top of the photobioreactor column are located photobioreactor columns entrusted with the task of redischarging the rolling path compound into the rolling path for the sake of assuring passage of gas bubbles or ensuring entry of more gas therein. The invention covered by the application mentions about an innovation made in respect of passage of gas bubbles in the method of production of microalgae by a channel type pond.

This system is an innovative invention which is created by combination of already existing methods and does not actually contain any novelty. There is no information as to how gas exit is ensured or controlled. It does not contain any logic expandable and enlargeable for production of great scales. It is exposed to contamination risk due to having open top.

The application with a publication number of CN203569083 (U) defines a photo reactor for a multi-channel, multiple raceway pond. Photobioreactor contains a raceway pond (1), a variable speed stirring system, a carbon dioxide production system (4) and a ground temperature control system. In comparison to the prior technique, this photobioreactor has the following advantages: (1) inclusion of a variable speed hydraulic stirring system into reactor design, so as to make the photobioreactor fit and convenient for microalgae cultures of different mechanical resistance types; (2) in comparison to a traditional motor, a great number of gateway ponds may be run and operated by means of a hydraulic stirring system, and thanks to this great scale application, both investment cost and operating energy consumption are reduced to a great extent; (3) a carbon dioxide compensation system is provided to reactor, and a degassing machine is fitted and installed on tail end of the compensation system, thereby prolonging the time carbon dioxide is kept in water, and increasing the rate of use of carbon dioxide by microalgae; (4) a plastic film layer is installed at the top of raceway pond, thus reducing the possibility and risk of contamination with foreign substances or organisms; and (5) thanks to adoption of the new system used to control temperature in circulation, cultivation time of microalgae in winter and summer months is prolonged, and in the meantime, energy consumption of reactor is reduced.

This invention also has all disadvantages of the existing raceway system. The risk of contamination is tried to be reduced by stretching a film layer over the newly developed pond. However, no information is given as to how this film layer will react to O2 and CO2 exits. Nor is any information given as to how this film layer to be manufactured of PVC will react to such natural events as snow and hail or to berry breaking rituals of birds.

According to patent document titled “solar bioreactor”, with a publication number of TR2014/ 13550, contained in the prior art, solar bioreactor is an invention relating to transmission of fixed-positioned light to outdoor/indoor bioreactors by means of fiberoptic cables and with the help of mirrors and lenses. It is basically designed in order to ensure that the column-type tank reactors can make use of daylight in daytime. It does not suggest a complete methodology. DEFINITION OF THE INVENTION

The basic purpose of the present invention is to overcome and resolve all of the problems and disadvantages mentioned in the prior art, thereby meeting and satisfying all needs of exchange of species, experimental use and continuous growth production, by taking into consideration all needs of both laboratory environment and commercial use and practice. The invention aims to fully resolve the cleaning and surface-clinging problems being the greatest problems of almost all of the existing types. The invention is also a system based on the principles of making highest use of sunlight by following sun through seasonal sun axis control for growth of photosynthetic organisms, as an alternative to the existing outdoor and indoor systems. Another purpose of the present invention is to create a new type of spherical photobioreactor developed for growth of photosynthetic organisms by using CO2 and waste water in both pressurized and non-pressurized environments with low voltage electrical energy stored in solar panels and by means of wind turbine at times of inadequate sunlight.

Yet another purpose of the present invention is to make sure that the systems make use of sunlight at maximum level thanks to a mobile carrier (conveyor) mechanism enabling the system to follow sun. The reflectors installed at the bottom and back parts are automatically positioned to reflect sunlights onto the relevant surfaces at an optimal angle, thus ensuring that photosynthetic organisms receive the most appropriate light from all directions at all times.

Another purpose of the present invention is to prevent intoxication and even death of organisms due to accumulation of O2 in the system through continuous and uninterrupted control and monitoring of the dissolved O2 content of system, and to automatically discard gas out in case of O2 content being above the desired level, and to assure recovery of CO2 escaping during this egress. Another purpose of the present invention is to ensure that at times of inadequate natural insolation, the same level of light is fed to photosynthetic organisms at all moments of day and year by means of full-spectrum light sources existing on four columns installed and placed in front and at the back of the system. And thanks to its fully automatic shell system, in bad weather conditions, it ensures full security of device, and enables the production and growth to be continued with its own light sources.

Yet another purpose of the present invention is to use an automatic sampling system in order to detect if and when photosynthetic organisms have reached the desired target size, and thus to follow up and determine growth and maturation process by taking pictures with the help of either fully automatic or remote control digital microscope and by performing a computer-aided size analysis. Through continuous registration of these data, the device can conduct all of segregation, classification, renewal, internal cleaning and refilling processes in a fully automatic manner if and when needed, and optionally, the device can automatically shift to harvesting process when organisms reach the desired target size.

Another purpose of the present invention is to ensure that prior to harvest, a desired portion of the production water is separated in advance, thus speeding up the harvesting process, and the separated water is transferred to a special reservoir, and such water is later used as irrigation water.

Another purpose of the present invention is to automatically transfer to a renewal process the organisms below the desired target size, and take them into settling tanks. Photosynthetic organisms of appropriate size are passed through a membrane filter replaceable according to types of organisms by a mobile scraping mechanism in a closed environment. Then, pH, heat, light, conductivity, dissolved O2 and dissolved CO2 values in the system are automatically measured, and the required controls and corrections are automatically made as per a certain algorithm assigned according to types of organisms, and all process steps are recorded.

Yet another purpose of the present invention is to make it possible to design the movements of organisms identically to their natural environment thanks to hang- gliders designed geodesically inside the generator. Due to their simple structure, it is easy to replace the gliders, and the number of whirlpool holes may be increased or decreased optionally.

Another purpose of the present invention is to build specially coated heat exchange plates positioned specifically at the top part of sphere for prevention of clinging of organisms thereon, in order to be able to increase or reduce the indoor heat if and when needed.

Another purpose of the present invention is to make sure that discharge ends are located at the ground of the system for discharge of CO2, and that these ends can be used as a stirrer if and when desired. Another purpose of the present invention is to realize the internal cleaning of system by stripping the whole internal surface by using pressurized water. Yet another purpose of the present invention is to separate the system structure originally designed as two semi-spheres into two parts in a motorized manner if and when deemed necessary, and thus, to be able to reach each point of the system at arm’s length for cleaning purposes, and to make sure that there is no point unreachable by arm at any part of the system.

Another purpose of the present invention is both to facilitate the continuous production processes and to provide facility in exchange of species thanks to its double settling tanks. Another purpose of the present invention is to provide maximum contamination protection after the system starts to operate thanks to its fully enclosed production, storage, segregation and discharge/exit tanks.

Another purpose of the present invention is to ensure that microorganisms are transferred and conveyed to the next process step under full protection and hygienic conditions thanks to its easy-to-dismantle and insulated product carriage tank.

Yet another purpose of the present invention is to ensure preparation of blends of 10 ml sensitivity by means of eight-tube electrolyte system for all kinds and types of conditioning, and to design the whole system fully open to further development works.

The present invention is a fully automatic system developed and built for growth of photosynthetic organisms, and has minimized the human labour. System makes maximum use of solar energy, and in addition, generates its own energy without need for any external energy source. System is easy to clean, and can conduct its simple cleaning fully automatically in itself. The whole production process is automatically recorded, thus facilitating the access to all information and data. System makes its own weather forecasts, and automatically takes itself under protection in emergencies, and the whole production process is uninterruptedly continued throughout this protection process. System is online linked to internet, and reports its own needs to its management centre, and conducts its own trouble shooting itself. All electronic components of the system are designed as twins. Thus, if and when the primary system breaks down, the redundant system is automatically activated, and sends the resulting error code online to the management centre. System continuously and permanently keeps all processes under record by creating a rapid, effective, efficient and repeatable invitro environment both in experimental works with exchange of species and in industrial type and scale production processes.

DRAWINGS

The present invention will be described with reference to the drawings attached hereto. By doing so, characteristics and specifications of the invention will be understood and appreciated better, but it must be kept in mind that the purpose of this choice is not to limit or restrict the present invention by such certain drawings or arrangements. On the contrary, it is intended to cover all alternatives, changes, modifications and equations which may be included inside the area defined by the claims of the present invention attached hereto. It should be noted that all details are shown and referred to solely for description of the preferred embodiments of the present invention and for making the most convenient and easily understandable and comprehensible description of both the shaping of methods and the rules and conceptual features of the invention. The drawings are as listed and defined hereinbelow:

Drawing 1 : Side view of the system in operation in closed position Drawing 2: Front view of the system in operation in closed position Drawing 3: Side view of the system in operation in open position Drawing 4: Front view of the system in operation in open position Drawing 5: Side view of operation mode position Drawing 6: Front view of operation mode position Drawing 7: Side view of sphere mechanism in closed position Drawing 8: Side view of sphere mechanism top sphere in open position Drawing 9: Side view of sphere mechanism top sphere in lateral open position Drawing 10: Side view of sphere mechanism top sphere in lateral open position and when turned by 180°

Drawing 11: Side view of gas foaming chamber and segregation department in operation position

Drawing 12: Front view of sphere mechanism in closed position Drawing 13: Front view of sphere mechanism top sphere in open position

Drawing 14: Front view of sphere mechanism top sphere in lateral open position Drawing 15: Front view of sphere mechanism top sphere in lateral open position and when turned by 180°

Drawing 16: Front view of gas foaming chamber and segregation department in operation position

Drawing 17: Side view of discharging channel and carriage department in operation position

Drawing 18: Segregation scraper and segregation vessel in closed position Drawing 19: Segregation scraper and segregation vessel in open position Drawing 20: Front view of rotating table and stirrer department in operation position

Drawing 21 : Top view of hang-glider stirrer Drawing 22: Side view of self-cleaning water extractor Drawing 23: Front view of self-cleaning water extractor Drawing 24: Front view of cleaning scraper and frame gear Drawing 25: Detailed view of automatic electrolytic liquefier Drawing 26: View of Eight Tube Automatic Electrolyte System (8toes)

Drawings used to help in better understanding of the present invention are numbered as shown in the pictures attached hereto, and are given below together with their names. Reference List:

1. CO2 and O2 Control System and Tanks

2. Outer shell Layer 1

3. Outer shell Layer 2 4. Outer shell Layer 3

5. Outer shell Layer 4

6. Gas Compressor

7. Weather Forecasting Station

8. External Air-conditioning Unit 9. Wind Turbine

10. Eight tube automatic electrolyte system (8toes) Protective Box

11. Solar Electricity Panel

12. Top Carrier Platform

13. Outer shell Front Casing 1 14. Outer shell Front Casing 2

15. Outer shell Front Casing 3

16. Outer shell Front Casing 4

17. Outer shell Front Casing 5

18. Settling Air Liquid Fleaters 19. Settling Tanks

20. Settling Tanks Bottom Gas Inlet

21. Settling Tanks Joint Gasket and Locks

22. Settling Tanks Gas Entry / Exit

23. Settling Clean Air Filter 24. Axial Bottom Reflector

25. Axial Back Reflector

26. Back LED Column

27. Sun Filter Back Coil

28. Sun Filter Lifting Arm 29. Sun Filter Lifting System

30. Sun Filter Arm Lock

31. Sun Filter Front Coil

32. Sun Filter 33. Sun Filter Tractive Conveyor

34. Internal Air-conditioning Unit

35. Front LED Column

36. Eight Tube Automatic Electrolyte System (8toes) 37. Production Scrap Gas Segregation System

38. Weight Sensor

39. Carrier Feet

40. Top Semi-sphere

41. Top Semi-sphere Spinning Motor 42. Top Semi-sphere Spinning Bed

43. Top Semi-sphere Carrier Bed

44. Top Semi-sphere Carrier Z Axis Motor

45. Top Semi-sphere Carrier Z Axis Ball Screw

46. Top Semi-sphere Loop Motor 47. Y Axis Rotator Motor

48. Y Axis Rack Gear

49. Bottom Sphere Bed

50. Bottom Semi-sphere Gasket Pulley

51. Bottom Semi-sphere Locks 52. Harvest Exit Chamber

53. Segregated Rearing Pond

54. Segregation Filter

55. Segregation Peristaltic Pump

56. Segregation Scraper Motor 57. Segregation Scraper

58. Segregation Vessel

59. Segregation Ball Screw

60. Rotary Table

61. Rotary Table Pivot Pin 62. Rotary Table Carrier Feet

63. Gas Foaming Chamber Separation Latch

64. Gas Foaming Chamber Gas Exit Connection

65. Gas Foaming Chamber Carrier Feet 66. Gas Foaming Chamber

67. Sun Light Sensors

68. Foaming Throttle

69. Foaming Filter 70. Post-foaming Feedback Connection

71. Sphere Internal Leakproof Self-cleaning Water Extractor Cock

72. Sampling Camera

73. Sampling Module

74. Leakproof Sensor Housings 75. Leakproof Cover

76. Cooling Water Outlet

77. Cooling Water Circulating Pump

78. Cooling Water Radiator and Fans

79. Cooling Water Trough 80. Discharging Channel

81. Discharging Channel Cock

82. Top Semi-sphere Gasket Pulley

83. Top Semi-sphere Locking Brackets

84. Semi-sphere Sealing Gaskets 85. Hang-Glider Stirrer Motor

86. Segregated Harvest Exit Chamber

87. Batteries

88. CO2 Jets

89. Gas Channel of CO2 Jets 90. Rotary Table

91. Rotary Table Pivot Pin

92. Rotary Table Axial Bearing

93. Rotary Table Carrier Feet

94. Internal Light Sources 95. Internal Refrigerator Impellers

96. Internal Refrigerator Bed

97. Top Shaft Housing

98. Jet Stream Internal Washing Pressurized Water Entry 99. Jet Stream Internal Washing Pressurized Water Channel

100. Jet Stream Internal Washing Duplex Head

101. Jet Stream Internal Washing Packing Sleeve

102. MCU (Micro Controller Unit) 103. Bearing Sub-carrier

104. Hot Entry

105. Cold Entry

106. Discharging Channel Sweepers

107. UPS (Uninterruptible Power Supply) 108. Product Carriage Tank

109. Top Holder Internal Cooling Impellers

110. Generator

111. Hang-Glider Stirrer Carrier Shaft

112. Hang-Glider Stirrer Top Carrier 113. Hang-Glider Stirrer Sub-carrier

114. Hang-Glider Stirrer Impellers

115. Cleaning Scraper and Frame Gear (front view)

116. Outlet Valve Servo

117. Cleaning Scraper Motor 118. Cleaning Scraper

119. Frame Gear

120. Membrane Filter

121. Membrane Filter Bed

122. Membrane Filter Bed Fagade Lining 123. Rotary Valve

124. Bearing

125. Dosage Motor

126. Water Entry Solenoid

127. Electrolyte Liquefier Reservoir 128. Dosage Gear

129. Electrolyte Stirrer Motor

130. Dosage Work Screw

131. Lifter Spring 132. Electrolyte Stirrer Propeller

133. X Axis Cartridge Select Motor

134. X Axis Cartridge Interlock Motor

135. X Axis Cartridge Axial Bearing 136. X Axis Cartridge Interlock Bed

DETAILED DESCRIPTION OF THE INVENTION

The preferred alternatives referred to in this detailed description of this invention are depicted and described herein solely for the sake of clarity and in such manner not to lead to any restrictive or limiting effect thereon.

This invention is developed for growth of photosynthetic organisms, as an alternative to the existing outdoor and indoor systems. The system is based on the principles of making highest use of sunlight by following sun through seasonal sun axis control. However, it is also designed as a new type of spherical photobioreactor developed for growth of photosynthetic organisms by using CO2 and waste water in both pressurized and non-pressurized environments with low voltage electrical energy stored in solar panels and by means of wind turbine at times of inadequate sunlight.

The steps of process from the stage the final product is obtained to the stage the invention is ready for new harvest production are described in details under certain headings in the following paragraphs:

Installation:

At the first stage, both name of device identified through network and such installation data as type of algae to be used for selection of basic calibrations and settings of the device are input to the central processor. Thus, in order to make its optimal settings on its existing equipments according to the selected type of algae, the device gets from the information bank such data as on and off times, motor speeds and temperature values. Then, the device reads from its RTC (real time clock) module such data as date and time preset ex-works.

Central processor checks the optimal installation and positioning of device by sending position and direction data to 32 bit MCU (micro controller unit) (102) according to the longest day. In case of a positioning error, central processor shows to the user to which direction the device should be turned by how many degrees. After this correction, the same process is repeated to check optimal positioning, and installation process is continued.

Then, central processor sends date, time, position and direction data to 32 bit MCU (102) for calculation of sun position information. This calculation is repeated at a certain predetermined time before sunrise every day. At each calculation, 32 bit MCU (102) sends to central processor not only sun position information of that day, but also sunrise time of the day after. Thus, the position zeroing (reset) time of the machine is calculated, and at which time the same step will be taken one day after is recorded and noted by central processor.

All of the data collected as above are registered in database MCU (102) linked to central processor. This MCU (102) transfers such data to a cloud server located in internet at a timing frequency to be determined by the manufacturer. Such data may be displayed by user offline and online via an interface provided by the manufacturer. Only the manufacturer is authorized to change or revise all such data. Users are by no means entitled to change or modify data either on MCU (102) or on cloud server.

After this point, the device starts energy situation control procedure for the sake of getting prepared for start-up procedure. Fill rates of both UPS (Uninterruptible Power Supply) (107) and batteries (87) are tested, and initial charging process is initiated, as done in all electronic devices. No other step is permitted to be taken until batteries (87) are filled by 100%. Filling process of batteries (87) is conducted by internal generator (110). By using the sensor installed on the internal generator (110) fuel tank, the device compares the quantity of fuel existing in the tank with the level of fuel needed for full charging of batteries (87), and if and to the extent needed, asks the user to supply fuel thereto.

After batteries (87) are filled by 100%, weather forecasting station (7) is opened, and conformity of minimum weather conditions required for installation is checked. If the conditions are not satisfied, such control is continued at certain time intervals to wait automatically for satisfaction of appropriate conditions. At this stage, no external intervention is done by any means or motives for continuation of the procedure.

When the weather conditions are satisfactory for installation, outer shell (2, 3, 4 and 5), wind turbine (9) and solar electricity panels (11) are opened. Energy control MCU (102) is activated, and it ensures and checks the charging of batteries (87) in consecutive order of solar electricity panels (11), wind turbine (9) and generator (110). And the resulting problems are reported to central processor. After this point, liquid and electronic connections of the device with external food tank are established.

With the intention of cleaning probable contamination of the device during transportation, the first cleaning water delivered by the manufacturer is filled in external food tank. The pressurized cleaning water motor pumps the first cleaning water coming to the internal tank into the sphere up to 10% level. Then, internal surface is cleaned by using Jetstream internal washing heads (100). Feedback line is opened, and cleaning water is fed into gas foaming chamber (66). When gas foaming chamber (66) maximum liquid level measurement probe gives a signal, algae recycling cock is opened, and cleaning water is transferred back to the main sphere. Water extractor and algae discharging channel cocks are opened, and first cleaning water is transferred into segregation pond and internal water tank. Cleaning water coming to the segregated rearing algae pond is pumped respectively to the right and left algae settling tanks (19), and is ensured to be cleaned in their tanks (19). After this stage, the water gathered at the down is transferred to internal water tank. All discharging cocks inside the sphere are closed. Cleaning water in the tank is passed through refrigerator and fed into the external surface cooling channel. Thus, outer face and cooling water trough of top sphere (40) are ensured to be cleaned. Then, water coming from here to waste water tank is removed from the system by opening the general discharging cock. At this point, second cleaning water (pure water) sent by the manufacturer is added to the system, and all process steps taken from the starting point of cleaning are repeated. After second cleaning water is discharged out of the system, segregation pond carrier filter is removed, and a segregation filter fit to the type of algae to be used therein is fitted, and then, the remaining electronic and mechanical components of the system are tested.

First, external and internal light columns (94) are lit in order, and minimum and maximum luminous intensities of each of them are measured by using the existing light measurement probes. Intensity values of all light sources are registered in the database. This process is repeated at each cleaning activity during operations, and situation of light sources is statistically checked. Determination of life of light sources is an indispensable step for achievement of the most appropriate production conditions.

Gas segregation system cocks and vacuum pumps are operated, and all vacuuming periods and all vacuum values are tested by means of pressure probes available in the system. These values are recorded in the database for detection of wears and tears that may occur during operations.

At this point, sun filter (32) system integrated into the system for protection from excessive light in very sunny days is checked. Filter (32) is entirely rolled out and rewound. Filter values arising during this process are recorded again by light probes (67) available on the system, and are registered in the database. Sun filter arm lock is unlocked, and is made 90° perpendicular by means of sun filter lifting arm (32) system. At the same time, back and bottom mirror motors are activated and rotated in all of their axials, and are checked by the existing rotation potentiometer sensors whether they reach their ex-works settings registered in the system or not. By doing so, all of the maintenance needs that may arise out of environmental pollution during operations are ensured to be determined correctly. Y axis rotator (47) is moved in both directions and brought to its maximum values. Thus, the operability of border keys is checked. Y axis rotator (47) has maximum movement and rotation ability by 105° angle in both directions. This angle is checked by means of rotation potentiometer sensor linked to rotary table carrier feet (93) carrying Y axis rotator (47). Any probable impairment of light balance of natural habitat is prevented by closing the outer shell (2, 3, 4 and 5) after sunset.

Closing sensors are tested by closing and reopening the top semi-sphere (40) locks. Then, top semi-sphere (40) locks are opened to check the upward and frontward inclination and tumble movements of top semi-sphere (40). Later, top semi-sphere (40) is replaced in locking position, and top semi-sphere (40) locks are closed. When all liquid and air cocks are closed, the system is vacuumed by opening gas foaming chamber (66) vacuum connection. Thus, leakage test is performed. Thereafter, sun filter arm (28) is brought to closed position and is locked.

Clean air passed through air filter is pumped into the sphere, and high pressure test is conducted on the system. Then, high pressure is discharged, and gas foaming chamber (66) gas flow is checked.

First hot, and then cold liquids are transferred into internal peat impellers, and heating and cooling values are measured by means of heat sensors inside the sphere. At this point, osmosis and operation tests of all primary and backup MCUs (102) are conducted by means of central and control MCU (102). Thus, tests of all general mechanical movements and electronic sensors of the system are completed. Commissioning:

After completion of all of the tests, the system is put on hold in a position ready for commissioning. The user places all algae cultures wished to be used into algae settling tanks (19). Then, the user selects the to-be-used algae type on the control panel, and waits until completion of system settings and display of “ready for operation” command. The user may start full automatic operation of the system by pressing start button. Thereafter, the system autonomously applies all procedural steps until completion of the process without a user command, except for any failure or breakdown therein.

Algae settling tanks (19) transfer cock fills in food liquid up to the level sensor from the connected external food tank into the sphere. At this point, the cock starts to inject algae culture into the sphere by automatically selecting tank (19) in each production cycle, starting from the algae settling tank (19), whichever is already selected. The transfer cock is closed after the culture is entirely discharged. Then, hang-glider stirrer (114) is started to be rotated in optimal level for prevention of precipitation. Food liquid transfer continues until the sphere is fully filled in. The system rotates Y axis towards sun by using the sun position information sent by 32 bit MCU (102) to control processor in reliance upon the available date, time, position and direction data. At this point, bottom and back mirrors are brought to optimal position according to position of sun. Light adequacy is tested by using light measurement probes (67) located on the system. If light comes more than the desired level, sun filter (32) is opened. If light comes less than the desired level, internal and external light sources (94) are opened. Light adequacy test is continued uninterruptedly during all of these operations. System inputs are started to be opened when adequate light is provided. First, CO2 is started to be input after completion of setting in a quantity fit to the selected type of algae. Then, hang-glider stirrer (114) is raised to the production speed to ensure equal distribution of C02 inside the sphere, protection of structural integrity of algae, and maximization of production efficiency. If an electrolyte such as NaOH, etc. is to be used for modification of conditioning in the production, its addition to the system is started at this point.

Starting from this point, cellular size and intensity measurement system is activated by means of all sensors available in the system. Then, light, CO2, O2, internal heat, pH and cellular surface temperature are started to be measured continuously at a frequency predetermined by the system. These data are registered in the database again at a frequency predetermined by the system. If any one of these values is detected to be out of the appropriate range, the following procedures are applied.

Gas foaming chamber procedure:

Through O2 and CO2 measures continuously repeated inside the sphere, whether CO2 level is kept at the desired level or not is checked by means of CO2 cycle valve. However, as O2 is a by-product produced by algae and as the increase of its level above the desired level will lead to inhibition of algae, if and when needed, gas foaming chamber gas exit cock (64) is opened, and liquefied CO2 and O2 are discharged out of the system. The foaming occurring during this discharge is held by the foaming filter positioned underneath the gas foaming chamber (66). Level is checked inside the chamber (66), and in case of liquid exit above the foaming filter level, the cock (64) is closed, and discharging operation is started. First of all, the cock located on the ground of chamber (66) is opened, and algae and food liquid available in the chamber (66) are sent back to the sphere by means of peristaltic pump. After completion of liquid discharge, the ground cock is closed, and the chamber (66) is interned. As soon as this process starts, the production waste gas segregation CO2 module is vacuumed. After completion of liquid discharge, the cock opening to CO2 module is opened, and CO2 - O2 mixture is vacuumed into this chamber. Gas is continued to be discharged by means of an auxiliary compressor (6) until the gas available in the chamber (66) is fully discharged. When gas mixture is fully discharged out of the chamber (66), CO2 module entry cock is closed. O2 module is also vacuumed concurrently. After CO2 entry cock is closed, two cocks between these two modules are opened, and O2 is let to enter into O2 chamber. When O2 is zeroed in CO2 chamber, the cock at entrance of O2 module is closed. O2 kept in O2 module is pumped into O2 tube by means of O2 vacuum compressor. Then, heater around CO2 filter installed between these two chambers is started to ensure expansion and enlargement of filter meshes. At this stage, vacuum compressor linked to CO2 module is operated for backfilling into CO2 tube. Thus, loss of CO2 is prevented. Then, all cocks are closed. Filter meshes are ensured to be re-narrowed by operating and running the Peltier refrigerator installed around the filter. Thus, it is made ready for next use thereof. The foam resulting from water feedback through foaming chamber filter is discharged out by means of the main water discharging channel at the desired frequency.

Internal temperature control:

Internal temperature control sensor, being one of the sensors positioned inside the sphere, aims to control heat changes caused by photosynthesis reactions occurring during production. This process is conducted in order to prevent impairment of cellular integrity of algae by heat changes. Heat range is determined according to the type of algae selected, and if temperature is detected to be below the desired value, hot liquid is transferred automatically to internal heat impellers, thus increasing the internal temperature. If temperature is detected to be above the desired value, likewise, cold liquid is transferred to internal heat impellers (95), thus reducing the internal temperature. Values recorded by means of this sensor are registered together with database time data at predetermined ranges and in case of detection of abnormal temperatures. pH temperature control: pH sensor, being one of the other sensors existing inside the sphere, controls and monitors acidity in the environment. pH level also changes in case of fluctuations in CO2 concentrations. CO2 cycle is rearranged by using the algorithm existing in the system according to the selected type of algae. If pH level cannot be corrected in spite of this action, pH is tried to be rearranged by addition of electrolytes fit to the selected type of algae. Values recorded by means of this sensor are registered together with database time data at predetermined ranges and in case of detection of abnormal temperatures. Surface temperature control:

Surface temperature control of sphere is an indispensable action for both prolongation of life of the system and better control of life environment of algae therein, because high temperature changes and fluctuations occurring in summer and winter months may also affect the material used in manufacturing of sphere. This in turn may shorten the life of sphere or lead to breakage therein. The system has a surface temperature control procedure of several stages aimed at protection from these effects. There are several temperature control probes installed and positioned on outer surface and monitoring the outer surface from various different angles. Thus, when surface temperature rises, sun filter (32) is opened, and overheating of surface by IR (infrared) rays of sun is tried to be prevented. If and to the extent this measure is not adequate, the surface temperature control system located around the top cover is activated, and cold water is started to be poured over the shell surface. This water is collected by means of circular ring- formed basin (trough) located over the sphere interconnection point, and is transferred to cooling water radiators (78) on the carried sidewalls. These radiators (78), just like the radiators used in automobiles, cool down the water by means of their fans (78) installed at the back of them. The water cooled down as above is again pumped into the surface temperature control system on the top cover for circulation purposes. If the temperature falls below the predetermined range, likewise, sun filter (32) is retracted. Surface temperature control system is closed. If the temperature continues to fall down, circulating water containing anti freeze is poured hot on the surface by being transferred to surface temperature control system positioned around the top cover after opening the heaters in the circulating pumps (77) located at the bottom sidewall. If none of these measures is adequate, or in case of sudden temperature changes, the system automatically closes the outer shell, and activates the air-conditioning system (8 and 34) inside the shell. Thus, the system is ensured to be protected as a whole.

Values recorded by means of this system are registered together with database time data at predetermined ranges and in case of detection of abnormal temperatures. Cellular intensity and dimension control:

The greatest problems of biomechanical production processes are related to the difficulties faced in reduction of human intervention factor in automation processes. However, in chemical reactions, it is far easier to supervise and control the measurement processes by means of electronic probes, because chemical reactions are completed in fixed periods of time under fixed conditions between starting and ending points. But in biology, life motion of living creatures is indeed a continuous process. Therefore, human eye and brain and decision making mechanism are required to be operated for separation of matured product ready for harvesting from a product in maturation process. In our system, an Al (artificial intelligence) software-based decision making mechanism is employed so as to make this process automatic.

To this end, we have developed a component named online sampling module. By using this module, samples are taken from algae living inside the sphere by making use of drifts created by hang-glider. Then, the samples taken as above are inserted into a narrowed observation area designed in the form of a snail, and cells per unit of area are counted. Later, large cell selected by Al software is enlarged to conduct a cellular diameter measurement. If the cellular diameter has reached the dimension desired for harvesting purposes, cells of this diameter within the predetermined tolerance range are counted inside the observation area. If the cells are determined to be at the desired number, harvesting process is started. All images taken and all counts made during these operations are to be registered in database together with a time stamp, and if desired, a harvesting approval is to be taken from control centre, or if preferred so, harvesting process is to be started automatically. If the samples are, however, not at the desired dimensions, the samples available in the sampling module are to be sent back to the sphere upon completion of cycle thereat. Also in this alternative, all images taken and all counts made during these operations are registered in database together with a time stamp. Harvesting Procedure:

Starting from the beginning of harvesting procedure, all control mechanisms and electronic components, save for hang-glider, of the system are put on hold. System automatically turns back to zero point at Y axis. Then, self-cleaning water extractor developed specifically by us starts to run and to discharge water out of the sphere separately from algae. Thus, water of a certain predetermined rate is ensured to be discharged according to the selected type of algae. By doing so, algae - water blend with increased intensity is transferred into algae segregation chamber through algae discharging channel cock. At this point, system starts to perform both its internal cleaning and its algae segregation together.

First of all, we are going to mention about internal cleaning process. Quantity discharged through flow sensor positioned inside algae discharging channel and quantity discharged through flow sensor positioned inside self-cleaning water extractor are compared to quantity noted from the system weight sensors (38), to understand and detect whether the system is entirely discharged or not. At this point, all discharging cocks are closed, and high pressure water is started to be fed into Jet Stream internal washing system (98, 99, 100 and 102) mentioned previously. Internal cleaning process is continued at the rate and for the period previously determined therefor. Thus, algae clinging on various different surfaces are ensured to be cleaned as much as possible. Then, this algae - water blend collected again at the bottom is intensified by means of self-cleaning water extractor. Later, it is transferred to algae segregator through algae discharging channel. At this point, if open cleaning is required, the sphere general cleaning opening procedure starts to run.

When intensified algae - water blend is taken into the segregation pond (53), the segregation scraper (57) starts its reciprocating motion in order to prevent accumulation and precipitation of algae. Algae segregation filter (54) lid is opened when the second water - algae blend transferred to pond together with cleaning operation conducted by means of jet stream (100) is added to the pond. Then, by reducing speed of segregation scraper (57), rearing algae are ensured to flow into the segregated rearing algae pond (53) at the bottom together with water. At this point, if deemed necessary according to the selected type of algae, segregation process is facilitated by replenishing with the water transferred into the water tank by means of self-cleaning water extractor. When segregation process is completed, rearing algae in the segregated rearing algae pond are transferred to algae settling tank (19) emptied by means of peristaltic pump (55). At this stage, algae segregation filter (54) lid is closed. Then, mature algae ready for harvesting process which have so far been separated from water and rearing algae in the segregation pond (53) by means of segregation scraper (57) are pushed into algae filling channel by opening the side lid of segregation pond (53). Mature algae inside the harvesting channel are pushed into algae harvesting tube by means of a tappet located on a worm gear shaft. This tube may contain 5 to 10 harvests depending on types of algae. In algae farms where multiple machinery are employed, these tubes are substituted by conveyors conveying the harvested algae into integrated algae - oil segregation system. However, in research facilities with a single machine, these tubes are used as carriers not exposed to any contamination risk for picking up the harvest segregated from water. At this stage, system is ready for new production. General open cleaning:

One of the basic purposes of our invention is to ensure an easy and perfect cleaning operation. That is why the system has been designed in the form of two semi-spheres entirely separable from each other.

Cleaning process is realized as follows: Bottom and back mirrors are taken to zero position. User manually separates gas foaming chamber (66) and other connections. This separation is controlled electronically. The process does not continue before completion of this separation. The process is continued only after user signs on the control panel that the separation is completed. Sun filter (32) system is controlled and closed. Sun filter lifting arm (28) lock is opened, and the arm is brought to perpendicular position. Top semi-sphere (40) locks are opened, and top semi-sphere (40) is raised to maximum level at its Y axis. By using axial motors, top semi-sphere (40) is brought to front by double axial motions so that gas foaming chamber (66) is left at the top. At this point, as gas foaming chamber (66) is at the top, its locks may be opened for manual cleaning. Foam filter may be removed, and cleaned or replaced. Then, user unlocks the lock. This locking process is also controlled electronically. The process does not continue before locking. The process is continued only after user signs on the control panel that the locking process is completed. Sphere is rotated by 180 degrees by using top semi-sphere (40) top axial motor (44). At this point, as gas foaming chamber (66) is at the bottom, and as the inside of top semi-sphere (40) is in front of user, the internal cleaning, maintenance and replacement operations may be performed. Furthermore, as the system is entirely opened and in safe position, user may go backwards to perform cleaning, maintenance and replacement operations on the bottom semi-sphere. The closing process is initiated after user signs on the control panel that the required processes are completed. Top semi-sphere axial motor (44) is turned back by 180 degrees, and gas foaming chamber (66) is brought to a position at the top. This positioning is controlled electronically. Then, top semi-sphere initiates its Y axis system movement to pull down the semi-sphere till its locking level. Then, locking system is activated to lock the sphere. Sun filter lifting arm is pulled down and locked. Both operations are controlled electronically. At this point, gas foaming chamber and other connections are expected to be realized by user. After it is electronically controlled whether connections are completed or not, system is vacuumed, and leakage test is conducted by checking the pressure difference. The process is deemed completed if the impermeability is fully provided.

Claims

1. This invention is related to an autonomous photobioreactor which can effect full environment-controlled natural environment simulation under seasonal sun control and controlled natural/artificial lighting conditions by using renewable energy sources for production of photosynthetic / aphotosynthetic monocellular or multicellular organisms, or production of biosimilar living organisms (algae, diatoms, etc.) or biosimilar tissues, characterized in that it contains and is composed of:

- At least one MCU (102) performing such functions of the device as following sun, controlling data information and energy, and sending work history data to the system; and

- At least one gas foaming chamber (66), one gas foaming chamber separation latch (63) and one gas foaming chamber gas exit connection (64) used for keeping CO2 level at the desired content; and

- At least one jet stream system (98, 99, 100 and 101) cleaning the device by a pressurized liquid; and - One segregation scraper (57), one segregation filter (54), one segregation scraper motor (56), one segregation peristaltic pump (55) and one segregation vessel (58) contained in algae rearing pond (53) used for segregation of algae; and

- One cooling water trough (79), one cooling water radiator and its fans (78), one cooling water circulating pump (77) and one cooling water exit outlet (76) used to ensure that water temperature is kept at the desired level; and

- At least one hang-glider stirrer (114) used for prevention of precipitation, equal distribution of CO2 inside the sphere, and protection of structural integrity of algae; and

- At least one eight-tube automatic electrolyte system (36) used for regulation of pH level; and

- At least one sun filter (32) used for shadowing sunlight; and - At least one back LED column (26), at least one front LED column (35) and at least one internal light source (94) employed in case of inadequate light; and

- At least one sampling module (73) used for controlling / testing the situation of algae; and

- At least one wind turbine (9), at least one solar electricity panel (11) and at least one generator (110) used for meeting the energy needs of the system.

2. According to claim 1, an autonomous photobioreactor, characterized in that:

- It is equipped by outer shell layers (2, 3, 4 and 5) and outer shell front casings (13, 14, 15, 16 and 17).

3. According to claim 1, an autonomous photobioreactor, characterized in that:

- It is equipped by at least one top semi-sphere spinning motor (41), one top semi-sphere spinning bed (42), one top semi-sphere carried bed (43), one top semi-sphere carrier Z axis motor (44) and one top semi- sphere carrier Z axis ball screw (45) allowing top semi-sphere (40) to open and move along its axes.

4. According to claim 1, an autonomous photobioreactor, characterized in that: - It is equipped by at least one sun filter lifting arm (28) sun filter lifting system (29), sun filter arm lock (30) and sun filter front coil (31) allowing sun filter (32) to move at the desired level and to remain fixed and stable if needed.

5. According to claim 1, an autonomous photobioreactor, characterized in that:

- It is equipped by at least one sunlight sensor (67) measuring the density of light received by the system.

6. According to claim 1, an autonomous photobioreactor, characterized in that:

- It is equipped by batteries (87) and UPS (107) where energy needed by the system is stored.

7. According to claim 1, an autonomous photobioreactor, characterized in that:

- It is equipped by at least one external air-conditioning unit (8) and at least one internal air-conditioning unit (34) keeping the temperature of the system at optimum level.