Periodic Reporting for period 2 - Cyanobacteria (Developing an organic fertilizer production system using nitrogen fixing Cyanobacteria)
Reporting period: 2021-08-01 to 2023-07-31
The global consumption of nitrogen-based fertilizers currently nears 110 million metric tons annually, primarily sourced from the Haber-Bosch process. This industry significantly depletes resources, utilizing 3-5% of the global natural gas supply and accounting for 1-2% of global energy expenditures. Moreover, it serves as a major contributor to global warming, releasing approximately 10 tons of CO2 for every ton of nitrogen fertilizer produced. Consequently, heightened concerns about environmental impact have spurred double-digit growth rates in organic agriculture in recent years (overlooking the COVID pandemic setback). Nevertheless, existing organic fertilizers available in the market are costly, unstable, and struggle to facilitate robust commercial growth in hydroponic greenhouses or advanced irrigation farms.
Our innovation represents a paradigm shift, generating nitrogen fertilizer in an efficient and environmentally friendly manner directly at the farm or greenhouse site. Through large-scale cultivation of cyanobacteria in a controlled environment, we harness solar energy to continuously extract nitrogen from the air. The harvested biomass undergoes automatic processing in an anaerobic digester, resulting in a nitrogen-rich effluent. This high-quality organic bioliquid fertilizer (BLF) has been successfully applied in our pilot hydroponic greenhouse for over a year.
This pioneering method revolutionizes the procurement of nitrogen inputs for greenhouses, pivoting from importing industrial products with a high CO2 footprint to sustainable, on-site production. Our vision aims to provide wholesome, superior-quality fresh produce by establishing an ecological network of hydroponic greenhouses across Europe. This endeavor harmonizes the sustainability of organic agriculture with the efficiency and high yields achievable through precision irrigation.
Our innovation represents a paradigm shift, generating nitrogen fertilizer in an efficient and environmentally friendly manner directly at the farm or greenhouse site. Through large-scale cultivation of cyanobacteria in a controlled environment, we harness solar energy to continuously extract nitrogen from the air. The harvested biomass undergoes automatic processing in an anaerobic digester, resulting in a nitrogen-rich effluent. This high-quality organic bioliquid fertilizer (BLF) has been successfully applied in our pilot hydroponic greenhouse for over a year.
This pioneering method revolutionizes the procurement of nitrogen inputs for greenhouses, pivoting from importing industrial products with a high CO2 footprint to sustainable, on-site production. Our vision aims to provide wholesome, superior-quality fresh produce by establishing an ecological network of hydroponic greenhouses across Europe. This endeavor harmonizes the sustainability of organic agriculture with the efficiency and high yields achievable through precision irrigation.
In the first term of the Cyanobacteria (CB) project, Growponics has advanced both its technical and commercial capabilities in accordance with the work packages (WP) detailed in the grant application. We have successfully completed our tasks, and met the objectives of the first project period.
These objectives are the management and coordination of the project development towards a robust, automation ready, commercial scale bioreactor system, with a high yield CB strain growing in optimal conditions. A system that can be commercialized first as a pilot beta site, and then as fully commercial solution for the production of high precision, liquid organic fertilizer.
Commercially, we are ready to deploy the first version of a pilot beta site, and have already begun preparations.
Technical:
We have progressed from small scale assays in flasks and in small columns, to a repeatable batch process in large scale (240L) columns, with a downstream process that converts the ammonia rich solution and the CB biomass to high grade, liquid organic fertilizer. This batch process was designed to be fully automatic, with both an indoor LED illuminated model, and an outdoor sunlight model. Automation and software have already begun to be developed, and implemented.
Commercial:
We have started to offer the CB bioreactor system to potential customers. Our first installations will serve as beta sites in various countries and climate conditions, to test its operation in the relevant environment. We are in advanced contact with several companies and organizations in Europe, the USA and Israel for the installations of such pilots during the second term of this project.
These objectives are the management and coordination of the project development towards a robust, automation ready, commercial scale bioreactor system, with a high yield CB strain growing in optimal conditions. A system that can be commercialized first as a pilot beta site, and then as fully commercial solution for the production of high precision, liquid organic fertilizer.
Commercially, we are ready to deploy the first version of a pilot beta site, and have already begun preparations.
Technical:
We have progressed from small scale assays in flasks and in small columns, to a repeatable batch process in large scale (240L) columns, with a downstream process that converts the ammonia rich solution and the CB biomass to high grade, liquid organic fertilizer. This batch process was designed to be fully automatic, with both an indoor LED illuminated model, and an outdoor sunlight model. Automation and software have already begun to be developed, and implemented.
Commercial:
We have started to offer the CB bioreactor system to potential customers. Our first installations will serve as beta sites in various countries and climate conditions, to test its operation in the relevant environment. We are in advanced contact with several companies and organizations in Europe, the USA and Israel for the installations of such pilots during the second term of this project.
We have successfully implemented a continuous process for cultivating nitrogen-fixing cyanobacteria on a 3000L scale in airlift column PBRs, marking a significant milestone in scalable growth of these organisms. Utilizing commercially grown nitrogen-fixing cyanobacteria for crop fertilization represents a pioneering step, setting aside the isolated use in rice paddy fields.
Our contributions extend beyond the state-of-the-art:
- Developing a reactor manifold that interconnects the columns into a unified PBR unit, allowing concurrent filling or harvesting. This manifold is integrated with a distribution system enabling culture withdrawal for harvesting and refilling with fresh medium.
- Automating inoculation, harvest, CIP and other process using an in-house developed software.
- Devising a method to mitigate radiation stress in low temperatures by manipulating culture containment conditions.
- Introducing a new technique that minimizes contamination and culture collapse.
The dissemination of this groundbreaking technology holds promise in combating climate change by transitioning fertilizer production away from the energy-intensive Haber-Bosch process to our sustainable method. It opens avenues for high-yield precision agriculture to embrace organic practices, and our industrial-scale fertilizer production aims to offer high-quality, cost-effective BLF suitable for diverse crop types. With widespread adoption, we foresee a substantial increase in the availability of organic fresh produce, positively contributing to public health and to the environment.
Our cyanobacteria cultivation platforms and production facilities will generate skilled technical employment opportunities. Furthermore, we anticipate our technology will serve as a catalyst for research and development initiatives exploring the vast potential of nitrogen-fixing cyanobacteria.
Our contributions extend beyond the state-of-the-art:
- Developing a reactor manifold that interconnects the columns into a unified PBR unit, allowing concurrent filling or harvesting. This manifold is integrated with a distribution system enabling culture withdrawal for harvesting and refilling with fresh medium.
- Automating inoculation, harvest, CIP and other process using an in-house developed software.
- Devising a method to mitigate radiation stress in low temperatures by manipulating culture containment conditions.
- Introducing a new technique that minimizes contamination and culture collapse.
The dissemination of this groundbreaking technology holds promise in combating climate change by transitioning fertilizer production away from the energy-intensive Haber-Bosch process to our sustainable method. It opens avenues for high-yield precision agriculture to embrace organic practices, and our industrial-scale fertilizer production aims to offer high-quality, cost-effective BLF suitable for diverse crop types. With widespread adoption, we foresee a substantial increase in the availability of organic fresh produce, positively contributing to public health and to the environment.
Our cyanobacteria cultivation platforms and production facilities will generate skilled technical employment opportunities. Furthermore, we anticipate our technology will serve as a catalyst for research and development initiatives exploring the vast potential of nitrogen-fixing cyanobacteria.