Description:TECHNICAL FIELD
[0001] The present disclosure relates to the field of biofilm-based carbon capture systems. In particular, the present disclosure relates to a biofilm panel for cultivating photosynthetic microorganisms, such as microalgae, in a photobioreactor for carbon dioxide sequestration.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present disclosure. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed disclosure, or that any publication specifically or implicitly referenced is prior art.
[0003] The increasing levels of greenhouse gas emissions, particularly carbon dioxide in the atmosphere, are a major contributor to climate change and global warming. The primary source of carbon dioxide emissions is the burning of fossil fuels for energy production, transportation, and industrial processes. To mitigate one or more adverse effects of climate change, various carbon capture technologies have been developed. These technologies can be broadly categorized into chemical and biological routes.
[0004] Chemical carbon capture methods often involve the use of solvents or other chemical agents to absorb carbon dioxide from industrial emissions. While effective, these methods can have significant environmental impacts due to the properties of the chemicals used and the energy required for the process. Additionally, the carbon footprint associated with the production and disposal of the chemicals can offset the benefits of carbon capture.
[0005] Biological carbon capture, on the other hand, utilizes natural processes, such as photosynthesis, to capture and sequester carbon dioxide. Photosynthetic microorganisms have shown great potential for carbon capture due to their high photosynthetic efficiency and rapid growth rates. Traditional systems for cultivating photosynthetic microorganisms, such as a photobioreactor, are typically suspension-based and have several limitations. These systems are complex in design, require significant maintenance, and occupy large areas when scaled up for one or more industrial applications.
[0006] As a result, the existing carbon capture systems built on a suspension-based photobioreactor for cultivating photosynthetic microorganisms are expensive, involve high energy consumption, and have significant operational costs and have large space requirements, which are not conducive for urban settings. Furthermore, the high energy and cost associated with harvesting microalgae from the systems built on the suspension-based photobioreactor may be prohibitive.
[0007] There is, therefore, a need for a biofilm-based photobioreactor to cultivate photosynthetic microorganisms, such as microalgae, for sequestering carbon dioxide.

OBJECTS OF THE PRESENT DISCLOSURE
[0008] A general object of the present disclosure is to provide a biofilm-based panel design for cultivating photosynthetic microorganisms in a carbon capture system.
[0009] Another object of the present disclosure is to provide an improved biofilm panel for photobioreactors that enhances the adherence and growth of photosynthetic microorganisms, such as microalgae, for efficient carbon capture.
[0010] Another object of the present disclosure is to provide the biofilm-based panel design for cultivating photosynthetic microorganisms that is optimized for efficiency, cost, easy maintenance, scalability, space requirements, and suitability.
[0011] Another object of the present disclosure is to address and overcome the limitations of existing photobioreactor systems by offering a simpler, more cost-effective, and lightweight apparatus that is easy to install, operate, and maintain.
[0012] Another object of the present disclosure is to provide a biofilm-based panel that use organic, inorganic, and/or other types fabric for promoting adherence and fluid flow retention.
[0013] Another object of the present disclosure is to provide lamination on at least one side of the panel to provide rigidity and support.
[0014] The other objects and advantages of the present disclosure will be apparent from the following description when read in conjunction with the accompanying drawings, which are incorporated for illustration of the preferred embodiments of the present disclosure and are not intended to limit the scope thereof.

SUMMARY
[0015] Aspects of the present disclosure relate to the field of biofilm-based carbon capture systems. In particular, the present disclosure relates to a biofilm panel for cultivating photosynthetic microorganisms in a photobioreactor for carbon dioxide sequestration.
[0016] In an aspect, a biofilm panel for a photobioreactor includes a substrate made of an fabric. The substrate may be laminated with a lamination material on at least one side thereof. The fabric may be any one of or a combination of jute or cotton. The system also includes a support assembly including one or more rods configured to support the substrate for vertical hanging. The substrate assembly may be assembled to form a loop around the one or more rods. Further, the substrate includes a first attachment means and a second attachment means, where the first attachment means is configured to secure one or more vertical edges of the substrate to provide stability during fluid flow over the substrate, and the second attachment means is configured to secure one or more horizontal edges of the substrate with the one or more rods of the support unit. The system may be configured such that the substrate enhances photosynthetic microorganism adherence and growth.
[0017] In an embodiment, the lamination material may be selected from any one of: raxine, a Low-Density Polyethylene (LDPE), a Polyvinyl Chloride (PVC), or coated fabric.
[0018] In an embodiment, the substrate may have a Grams Per Square Meter (GSM) range of 100-400, and the fabric may have a weave type as a plain weave or a cross weave.
[0019] In an embodiment, the fabric may have an End Per Inch (EPI) range of 14-200 and a Pick Per Inch (PPI) range of 14-200.
[0020] In an embodiment, a culture of the photosynthetic microorganisms may be circulated by a fluid flow unit across a surface of the substrate, enabling the culture to adhere to at least one or more grooves of the substrate and proliferate on the surface of the substrate.
[0021] In an embodiment, the one or more grooves of the substrate may be configured to retain a fluid flowed over the substrate, facilitating the adhesion of the photosynthetic microorganisms to the one or more grooves.
[0022] In another aspect, a photobioreactor includes one or more biofilm panels, where each of the biofilm panels includes a substrate made of fabric whereon the photosynthetic microorganisms adhere to and grow. The photobioreactor may also include a fluid flow unit having a fluid flow pipe positioned above the one or more biofilm panels to distribute fluid evenly over the substrate of the one or more biofilm panels. The photobioreactor may further include a bottom tray positioned below the one or more biofilm panels to collect fluid that flowed thereover. The bottom tray is connected to the fluid flow unit to facilitate the recirculation of fluid collected from the substrate of the one or more biofilm panels.
[0023] In an embodiment, the photobioreactor may include a mechanical scraper system configured to remove excess photosynthetic microorganisms from the substrate of the one or more biofilm panels, where the mechanical scraper system is adjustable to vary a scraping speed based on the material properties of the substrate.
[0024] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF DRAWINGS
[0025] The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0026] FIG. 1 illustrates an exemplary representation of a film-based system for cultivating photosynthetic microorganisms for carbon dioxide sequestration, in accordance with an embodiment of the present disclosure.
[0027] FIGs. 2A and 2B illustrate an exemplary representation of a biofilm panel for the photobioreactor, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0028] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0029] Embodiments explained herein relate generally to cultivation of photosynthetic microorganisms. In particular, the present disclosure relates to a biofilm panel design for cultivating photosynthetic microorganisms, such as microalgae, in a photobioreactor for carbon dioxide sequestration.
[0030] In an aspect, a biofilm panel for a photobioreactor includes a substrate made of an fabric such that the substrate is laminated with a lamination material on at least one side thereof. The system may also include a support assembly comprising one or more rods configured to support the substrate for vertical hanging. The substrate assembly may be assembled to form a loop around the one or more rods. The substrate may be configured to enhance the photosynthetic microorganism adherence and growth.
[0031] In another aspect, a photobioreactor having one or more biofilm panels is disclosed. Each of the one or more biofilm panels includes a substrate made of fabric whereon the photosynthetic microorganisms adhere to and grow. The photobioreactor also includes a fluid flow unit comprising a fluid flow pipe positioned above the one or more biofilm panels to distribute fluid evenly over the substrate of the one or more biofilm panels. Further, the photobioreactor includes a bottom tray positioned below the one or more biofilm panels to collect fluid flowed thereover. The bottom tray is connected to the fluid flow unit to facilitate the recirculation of fluid collected from the substrate of the one or more biofilm panels. Furthermore, the photobioreactor may include a mechanical scraper system configured to remove excess photosynthetic microorganisms from the substrate of the one or more biofilm panels.
[0001] Various embodiments of the present disclosure will be explained in detail with reference to FIGs. 1-2B.
[0032] FIG. 1 illustrates an exemplary representation of a film-based system 100 for cultivating photosynthetic microorganisms for carbon dioxide sequestration, in accordance with an embodiment of the present disclosure. The system 100 may include a holding tank 110 that stores a fluid, an air ventilation unit 120, a pump 135, a film-based reactor 160 having one or more biofilm panels (such as biofilm panels 200 shown in FIGs. 2A and 2B), a monitoring and control unit 180, and lighting units 190A and 190B (collectively referred to as lighting unit 190). Further, the air ventilation unit 120 may include an air filter module 122 and an exhaust fan 126. In an embodiment, the pump 135 may be placed inside the holding tank 110. In an embodiment, the system 100 may also include a feed line 140 and a return line 175 that circulate the fluid from the holding tank 110 to the film-based reactor 160. The system 100 may also include solar panels 195 for providing energy to the system 100. Further, the holding tank 110 may include a mixing tube 115 configured to the pump 135.
[0033] In an embodiment, the holding tank 110 may be used to store the fluid. In an embodiment, the holding tank 110 may include consortia of photosynthetic microorganisms dispersed in the fluid. In an embodiment, the consortia of photosynthetic microorganisms of includes one or more cultures of one or more distinct species of photosynthetic microorganisms dispersed in the fluid. For instance, the consortia of photosynthetic microorganisms may include, but not be limited to, any one or more cultures of microalgae, cyanobacteria, and the like. The photosynthetic microorganisms may be procured from sources known to those skilled in the art. In an embodiment, the photosynthetic microorganisms may be optimally dispersed in the fluid stored in the holding tank 110 to maintain the optimal turbidity. In an embodiment, the fluid may be any one of water, nutrient-enriched fluid, and the like. For instance, the fluid may include nitrogen, phosphorous, potassium, and other growth promoting compounds.
[0034] In an embodiment, the pump 135 may be configured inside the holding tank 110. In an embodiment, the system 100 includes a mixing tube 115 having one or more nozzles, the mixing tube 115 configured to the pump 135 such that the fluid pumped through the mixing tube 115 by the pump 135 exits the mixing tube 115 through the one or more nozzles for mixing the photosynthetic microorganisms within the fluid in the holding tank 110, thereby evenly dispersing the photosynthetic microorganism in the fluid and at the same time avoiding any settling in holding tank. In an embodiment, number, shape, orientation, and placement of the one or more nozzle on the mixing tube 115 may be determined to ensure the culture of photosynthetic microorganisms are evenly dispersed in the fluid and prevent the photosynthetic microorganisms from settling and clogging in any part of the holding tank 110, based on size & volume of the holding tank 110, composition of fluid and strain of the photosynthetic microorganism, among other requirements. For example, the at least one nozzle may be defined on the mixing tube 115 at a 45-degree angle with respect to a longitudinal axis (i.e., in a lengthwise direction) to prevent the photosynthetic microorganisms from settling on and clogging the at least one nozzle. Further, the pumping force of the pump 135 may be suitably determined to minimize stress caused to the photosynthetic microorganism.
[0035] In an embodiment, the air ventilation unit 120 may be configured to circulate air within the system 100. In an embodiment, the air ventilation unit 120 draws ambient air 124 from an external environment into the system 100, and expels internal air from the system 100. In an embodiment, the air ventilation unit 120 may include the exhaust fan 126 that circulates air within the system 100 through forced air ventilation. In an embodiment, the air ventilation unit 120 includes the exhaust fan 126 that expels air from the system 100 such that the ambient air 124 from the external environment into the system 100 is drawn into the system 100 through an inlet, thereby providing the photosynthetic microorganisms adhered to the one or more biofilm panels 200 (as shown in FIGs. 2A and 2B) with ambient air 124 having gases that are conducive for growth of the photosynthetic microorganisms. In such embodiments, the gases may include, but not be limited to, carbon dioxide, and the like. In some embodiments, the biofilm panels 200 may be placed inside an enclosure 198. In such embodiments, the air within the enclosure 198 may be replaced by ambient air from outside the enclosure 198. In an embodiment, the air ventilation unit 120 may include the air filter module 122 configured proximately to an inlet that filters particulate matter microbial contaminants, and volatile compounds that contaminate the consortia of photosynthetic microorganisms in the system 100 from the ambient air 124 drawn in by the air ventilation unit 120. In an embodiment, the system 100 may be deployed in any urban and rural locations including, but not limited to industries, institutions, airports, railway stations, metro stations, societies, transport depots that have carbon dioxide in the ambient air in the external environment. For example, the system 100 may be deployed on the divider of a road, such that the air ventilation unit 120 draws ambient air 124 having carbon dioxide emitted by vehicles, and expels air oxygenated by the photosynthetic microorganisms in the system 100 back to the external environment. In other embodiments, the biofilm panels 200 may be exposed to the external environment, thereby not requiring the enclosure 198 as shown in FIGs. 2A and 2B. In such embodiments, the air ventilation unit 120 may be configured to draw air having gases like carbon dioxide from a carbon dioxide source (such as vehicle effluents, industrial effluents, and the like), push air oxygenated by the film-based reactor 160 away from the system 100.
[0036] In an embodiment, the pump 135 may be configured to draw the fluids from the holding tank 110 and circulate the fluids to the one or more biofilm panels 200 in the film-based reactor 160 through the feed line 140. In an embodiment, the pump 135 may be any one of including, but not limited to, centrifugal pump, submersible pump, and the like. In an embodiment, the pump 135 may further include a suction that sucks the fluid from the holding tank 110, and one or more outlets with at least one of the outlets coupled to the feed line 140 and at least one of the outlets coupled to the mixing tube 115. In such embodiments, the pump 135 may be used for pumping the fluid to both the one or more biofilm panels 200 through the feed line 140 and mixing the photosynthetic microorganisms in the holding tank 110. Further, the specifications of the pump 135 may be selected based on the power requirements of circulating the fluid through the feed line 140 and the mixing tube 115. In an embodiment, the feed line 140 may release the fluids circulated by the pump 135 on the one or more biofilm panels 200 such that the photosynthetic microorganism therein adheres to the surface the one or more biofilm panels 200. In an embodiment, the one or more biofilm panels 200 may also be connected to the return line 175 that returns the excess fluid from the one or more biofilm panels 200 to the holding tank 110. In an embodiment, the feed line 140 and the return line 175 may be any one of including, but not limited to, pipes, tubes, ducts, channels, and the like, that may connect the pump 135 to the one or more biofilm panels 200, and the one or more biofilm panels 200 to the holding tank 110 respectively.
[0037] In an embodiment, the feed line 140 may include at least one header pipe (shown using downward arrows from the feed line 140) extending towards the corresponding biofilm panels 200, each of the at least one header pipes having one or more discharge ports that controllably release the fluids circulated by the pump 135 across the surface of the corresponding biofilm panels 200 such that as the fluid is released the photosynthetic microorganisms therein adhere to and grow on the surface of the biofilm panels 200. In an embodiment, the monitoring and control unit 180 may be configured to control the volume of the fluid circulated by the pump 135 from the holding tank 110 to the one or more biofilm panels 200 over a predetermined time interval by controlling a desired cycle time associated with the pump 135, where the desired cycle time may be determined based on the type of photosynthetic microorganism used, the stress profile of the photosynthetic microorganism, the type of biofilm panels 200, and the desired growth rate of the photosynthetic microorganism. Further, the cycle time may be adequately controlled to prevent the photosynthetic microorganism from washing off from the surface of the one or more biofilm panels 200. In an embodiment, the film-based reactor 160 may include one or more biofilm panels 200 that allows the photosynthetic microorganisms in the fluid circulated by the pump 135 to accumulate and grow on a surface of the one or more biofilm panels 200.
[0038] In an embodiment, the system 100 may include a collection unit/bottom tray (such as bottom tray 210) configured to collect recirculated excess fluids from the one or more biofilm panels 200 and return the collected fluid to the holding tank 110 via the return line 175. In an embodiment, the bottom tray 210 may be indicative of a basin, tray or pipe that collects the excess fluid from the biofilm panels 200. In an embodiment, the bottom tray 210 may be placed proximately below the biofilm panels 200. In an embodiment, the return line 175 may be configured to return the collected fluid to the holding tank 110.
[0039] In an embodiment, the lighting unit 190 may emit light for the photosynthetic microorganisms. In an embodiment, the lighting unit 190 includes one or more light emitters configured in a lattice arrangement or any other lighting modules within the system 100. In an embodiment, the at least one light emitters may be Light Emitting Diodes (LEDs) that emit photosynthetic active radiation required to promote growth and photosynthetic activity of photosynthetic microorganisms. In other embodiments, the at least one light emitters may be any one or combination of including, but not limited to, incandescent lamps, filament lamps, florescent lamps, plasma lamps, artificial sunlight, solar simulators, and the like. In an embodiment, the one or more light emitters of the lighting unit 190 may be configured to controllably emit light at a predefined set of spectral attributes of light for promoting growth of the photosynthetic microorganism and direct air carbon dioxide sequestration. In an embodiment, the set of spectral attributes includes predefined ranges of intensity, irradiance, wavelength, and luminous exposure of light emitted by the lighting unit 190. In an embodiment, the one or more spectral attribute of light may be controlled by the monitoring and control unit 180.
[0040] In an embodiment, controllably emitting specific wavelengths of light may also allow for energy savings while also promoting growth of the photosynthetic microorganisms. For example, instead of emitting white light containing all wavelengths of visible light, the lighting unit 190 may be configured to only emit blue light and red light that may be required for the growth of the photosynthetic microorganisms. In such examples, the lighting unit 190, by not emitting energy intensive white light, may achieve energy savings while providing light that is required to promote the growth of such organisms. In an embodiment, the lighting unit 190 may be configured to emit blue light and red light (or light of any other wavelength in the absorption spectrum of photosynthesis), which may maximize photosynthetic active radiation (PAR) for the photosynthetic microorganisms.
[0041] In an embodiment, shape, size and orientation of the one or more light emitters may be optimized for promoting the growth of the photosynthetic microorganisms. For instance, the one or more light emitters may have a lattice arrangement that maximizes irradiance inside the system 100. In other embodiments, the one or more light emitters may be suitably arranged to maximize internal irradiance based on positions of each of the one or more biofilm panels 200. In an embodiment, the monitoring and control unit 180 may control the spectral attributes of light emitted by the one or more light emitters by transmitting signals based on the growth state of the photosynthetic microorganism. In an embodiment, the lighting unit 190 may also include a heat sink that may dissipate heat from the lighting source 190, thereby allowing lighting unit 190 to function efficiently.
[0042] In an embodiment, the system 100 may include a plurality of sensors configured to determine and transmit a set of data packets indicative of one or more environment parameters associated with the system 100 to a monitoring and control unit 180. In an embodiment, the monitoring and control unit 180 may be configured to control one or more of volume of air drawn in from the external environment by the air ventilation unit 120, the spectral attributes of the light emitted by the lighting unit 190, volume of fluid circulated by the pump 135 from the holding tank 110 to the one or more biofilm panels 200 over a predetermined time interval, and the like, based on the set of data packets received from the plurality of sensors. In an embodiment, the control unit 180 may be any one of a controller, a microprocessor, a digital signal processor, an application specific integrated circuit (ASIC), a digital logic circuit, a programmable logic controller, field programmable gate array (FPGA), or any combination thereof. In an embodiment, the monitoring and control unit 180 may also include an interface that allows operators to monitor and control the system 100. The interface may include a variety of input/output devices that allow operators of the system 100 to exchange data packets with the system 100. In an embodiment, interface may be implemented as a user interface including, but not limited to, a Graphical User Interface (GUI), an Application Programming Interface (API), a Command Line Interface (CLI), and the like. In an embodiment where the interface is implemented as a GUI, the monitoring and control unit 180 may also include a display device including, but not limited to, a monitor, projector, touch-screen display, and the like.
[0043] In an embodiment, the one or more environment parameters including, but not limited to, fluid level in the holding tank 110, carbon dioxide and oxygen levels in the system, spectral attribute of light to which the biofilm panels 200 are being exposed, and pH, temperature, turbidity, physiochemical profile, nutrient levels and DO levels of the fluid. In an embodiment, the monitoring and control unit 180 and the plurality of sensors may be configured in a closed feedback loop such that the plurality of sensors provides the monitoring and control unit 180 with environment parameters in real time. In an embodiment, the monitoring and control unit 180 determines if the environment parameter is beyond a predetermined threshold range, and accordingly transmits signals to corresponding elements of the system 100 to bring the measured attribute value within the predetermined threshold range. For example, an air DO sensor from the plurality of sensors may measure the DO levels in the air inside the enclosure 200. In an embodiment, the set of data packets may also be stored on a database to generate reports. In such embodiments, the set of data packets may be used for determining the efficiency of the system 100, and determine which components of the system 100 require maintenance.
[0044] In an embodiment, the holding tank 110 may also include a heating unit 118 that maintains the fluid therein at a temperature conducive to promote growth and maximize photosynthesis of the photosynthetic microorganism. In an embodiment, the heating unit 118 may include, but not be limited to, an electric heater, a microwave heater, an infrared heater, a combustion heater, a heater connected to an external source of energy such as a heat exchanger, a solar energy heater, a geothermal energy heater, and the like. In an embodiment, the holding tank 110 may also include a temperature sensor coupled to the monitoring and control unit 180, such that when the temperature of the fluid in the holding tank is outside a predetermined threshold range, the monitoring and control unit 180 transmits a signal to the heating unit 118 to increase or decrease the temperature of the fluids in the holding tank 110.
[0045] In an embodiment, the system 100 may include a wired or wireless communication means (not shown) for being in communication with a computing device for remote control of the device 100. The communication means may include, but not be limited, to various communication technologies such as a Bluetooth, a Zigbee, a Near Field Communication (NFC), a Wireless-Fidelity (Wi-Fi), a Light Fidelity (Li-FI), a carrier network including a circuit-switched network, a public switched network, a Content Delivery Network (CDN) network, a Long-Term Evolution (LTE) network, a New Radio (NR), a Narrow-Band (NB), an Internet of Things (IoT) network, a Global System for Mobile Communications (GSM) network and a Universal Mobile Telecommunications System (UMTS) network, an Internet, intranets, Local Area Networks (LANs), Wide Area Networks (WANs), mobile communication networks, combinations thereof, and the like. The computing device may be located at a remote location and may include a processor, a memory, and a communication means for receiving and transmitting data. Further, the computing device may be connected to one or more networks for communicating with the system 100. In an embodiment, the communication means may allow the operator of the system 100 to remotely control and maintain the system 100.
[0046] In some embodiments, the film-based reactor 160 may be a biofilm-based photobioreactor that may be employed in outdoor photobioreactor systems for large-scale biomass cultivation. The photobioreactor is a specialized system designed for cultivating photosynthetic microorganisms for carbon dioxide sequestration in a carbon capture system. The photobioreactor may provide an optimal environment for the growth of microorganisms, such as microalgae or cyanobacteria, that perform photosynthesis to sequester carbon dioxide in the carbon capture system. The photosynthetic microorganisms utilize light and water to convert carbon dioxide into biomass, thereby capturing carbon from the environment or industrial emissions.
[0047] In one or more embodiments, multiple ones of the system 100 or multiple ones of the film based reactor 160 may be modularly arranged. In some embodiments, multiple ones of the system 100 or the film-based reactor 160 may be stacked vertically, or arranged adjacently to each other to form an assembly. Such assemblies may be suitably adapted for scaling the photobioreactors to process larger volumes of carbon or to produce larger volumes of biomass.
[0048] In an embodiment, the photobioreactor may include one or more biofilm panels 200 configured to provide a high surface area for the growth and adherence of microorganisms. The photobioreactor includes a fluid flow unit 208 having a fluid flow pipe 216 (similar to the feed line 140) positioned above the one or more biofilm panels 200 to distribute fluid evenly over the substrate of the one or more biofilm panels 200. The fluid may be circulated through the fluid flow pipe 216 by the pump 135 in the holding tank 110. Further, photobioreactor 160 includes the bottom tray 210 positioned below the one or more biofilm panels 200 to collect fluid flowed thereover. The bottom tray 210 may be connected to the fluid flow unit 208 to facilitate the recirculation of fluid collected from the substrate of the one or more biofilm panels 200. Further details of the biofilm panels 200 are provided in reference to FIGs. 2A and 2B.
[0049] FIGs. 2A and 2B illustrate an exemplary representation (i.e., front and side views, respectively) of the biofilm panels 200 used in the photobioreactor/film-based reactor 160, in accordance with an embodiment of the present disclosure. In an embodiment, the biofilm panel 200 may include a substrate 202 made of a fabric. The substrate 202 may be a key component of the biofilm panel 200, acting as a primary surface designed to support the adherence and growth of photosynthetic microorganisms, such as microalgae or cyanobacteria. The substrate 202 may be made of fabric, which may be jute, cotton, and the like, or a combination thereof. The fabric may be made of organic, inorganic, and/or other type of fabric. The fabric may have a plain weave or a cross weave, which offers a suitable surface for microorganism attachment.
[0050] In an embodiment, the fabric may have an EPI range of 14-200 and a PPI range of 14-200, thereby ensuring the appropriate density and texture for microorganism growth. The EPI and the PPI may be suitably adapted based on the requirements of the use case. The fabric may be chosen for its natural properties that may provide an optimal texture for the adherence of photosynthetic microorganisms and growth. The use of fabric (and its natural properties) may allow the substrate 202 to retain (such as through absorption/adhesion) the fluid therein, which may facilitate the growth of the photosynthetic microorganisms. Furthermore, the fabric may include one or more pores or grooves that further facilitate adhesion of the photosynthetic microorganisms to the surface of the substrate 202.
[0051] In an embodiment, one side of the substrate 202 may be laminated with a lamination material, to control permeability or to provide structural integrity. The lamination material may be any one or a combination of including, but not limited to, raxine, a Low-Density Polyethylene (LDPE) or a Polyvinyl Chloride (PVC), coated fabric, and the like. The lamination may provide durability and/or resistance to continuous fluid flow over the substrate 202. Further, the substrate 202 may have a Grams Per Square Meter (GSM) range of 100-400, providing the necessary thickness and strength.
[0052] In an embodiment, the biofilm panel 200 may also include a support assembly 204 that includes one or more rods 206. The support assembly 204 may be configured to hold the substrate 202 in a vertical hanging position, allowing fluid to flow over it efficiently. The vertical orientation of the substrate 202 optimize exposure to light and nutrient-containing fluid flow for the photosynthetic microorganisms adhered to the substrate 202. The support assembly 204 may include the one or more rods 206 (made of steel, for example) that provides the necessary strength and stability to support the substrate 202. The substrate 202 may be arranged to form a loop around the one or more rods 206 to ensure a sturdy attachment and ease of assembly/disassembly for cleaning or maintenance. In one or more embodiments, substrate 202 may be looped around the rods 206 such that the laminated side/surface is on an inner side of the substrate 202 forming a loop, and the non-laminated side is on the outer/lateral surface of the loop formed by the substrate 202. In other embodiments, the laminated material may be sandwiched between two fabrics. In such embodiments, the fabrics may be exposed to the external environment, while the laminated material may be internally disposed between both the fabrics. In such embodiment, ends of the consolidated substrate 202 formed by the fabrics encapsulating the laminated material may be attached to the rods 206. The outer/lateral surface may be configured to allow the photosynthetic microorganisms to adhere thereover. Looping the substrate 202 around the rods 206 may maximize the surface area available for the photosynthetic microorganisms to adhere to in each of the biofilm panel 200.
[0053] In an embodiment, the biofilm panel 200 may further include a first attachment means 212 and a second attachment means 214. The first and second attachment means 212 and 214 may be configured to secure the substrate 202 to the support assembly 204 and provide stability during fluid flow. The attachment means 212 may be any one or a combination of, stitches (indicated by dashed lines), staples, adhesives, pins, clamps, clips, and the like, but not limited thereto. One or more vertical edges of the substrate 202 may be secured using the first attachment means 212 to keep the panel steady and prevent warping or misalignment during fluid flow over the substrate 202. One or more horizontal edges may be secured using a second attachment means 214 to secure the horizontal edges of the substrate 202 with the one or more rods 206 of the support assembly 204. The second attachment means 214 around the horizontal edges may ensure the substrate 202 is firmly attached and can withstand the weight of the fluid and microorganisms. The attachment means 212 and 214 may ensure that the fluid flowed over the substrate 212 is not collected between the laminated surface/inner side of the looped substrate 202, and that the fluid flows over the outer/lateral surface of the substrate 202.
[0054] In an embodiment, the biofilm panels 200 may be formed in any suitable shape, size and texture that may be conducive for the photosynthetic microorganisms to adhere to the surface of the biofilm panels 200 and grow. In an embodiment, the one or more biofilm panels 200 may also be treated or coated with a material, such as a hydrophilic layer, that facilitates adhesion and growth of the photosynthetic microorganisms. In an embodiment, the photosynthetic microorganisms growing on the surface of the one or more biofilm panels 200 may utilize the carbon dioxide in the air drawn into the enclosure 200, the fluids circulated by the pump 135, and light emitted by the lighting unit 190, and nutrients to photosynthesize and sequester carbon dioxide.
[0055] In an embodiment, a culture of the photosynthetic microorganisms may be circulated across the surface of the substrate 202, enabling the culture to adhere to at least one of the grooves of the substrate 202. The photosynthetic microorganisms may flourish on the surface of the substrate 202 and may utilize natural light (or the light emitted by the lighting unit 190), and captured carbon dioxide to perform photosynthesis. Furthermore, the one or more grooves of the substrate 202 may retain the fluid flowed over the substrate 202 to facilitate the adhesion of the photosynthetic microorganisms to the one or more grooves.
[0056] As stated, the photobioreactor/film-based reactor 160 may also include the fluid flow unit 208, having the fluid flow pipe 216 positioned around the one or more biofilm panels 200. A portion of the fluid flow pipe 216 is routed above the substrate 202 to distribute water evenly over both sides (i.e., the outer/lateral surface) of the substrate 202. The fluid flow pipe 216 ensures a steady flow of nutrient-rich liquid over the one or more biofilm panels 200, supplying the necessary nutrients for microbial growth and washing away waste products. Further, the fluid flow unit 208 may be configured to maintain a neutral or slightly higher (i.e., greater than 7) pH level to prolong the life of the substrate 202.
[0057] In an embodiment, the photobioreactor/film-based reactor 160 may include the bottom tray 210 positioned below the one or more biofilm panels 200. The bottom tray 210 collects excess fluid and any detached microorganisms. The bottom tray 210 is connected to the fluid flow unit 208 to facilitate the recirculation of fluid collected from the substrate 202 of the one or more biofilm panels 200. The bottom tray 210 prevents nutrient loss by recirculating the fluid back into the photobioreactor/film-based reactor 160.
[0058] In an embodiment, the photobioreactor/film-based reactor 160 may include a mechanical scraper system (not shown) configured to remove excess microorganisms from the substrate 202. The scraper system may be adjustable to vary the scraping speed based on the material properties of the substrate 202 to ensure efficient and gentle removal of excess microorganisms without damaging the substrate 202.
[0059] In an embodiment, the photosynthetic microorganisms growing on the surface of the one or more biofilm panels 200 may utilize the carbon dioxide in the air, the fluids circulated through the fluid flow unit 208, and an ambient light, to photosynthesize and sequester carbon dioxide from the air.
[0060] In some embodiments, the photobioreactor/film-based reactor 160 may present a highly cost-effective solution for large-scale carbon capture and biomass production. The innovative design of the one or more biofilm panels 200 may minimize material and operational costs by utilizing fabrics like jute or cotton, which are inexpensive and naturally suitable for microorganism adherence and growth. Furthermore, the use of the fluid flow unit 208 for recirculation may optimize fluid and nutrient consumption, ensuring sustainable operation with minimal resource expenditure.
[0061] In some embodiments, the photobioreactor/film-based reactor 160 may be engineered to operate with minimal energy consumption, leveraging natural light for photosynthesis and gravity-assisted vertical fluid flow to minimize energy-intensive pumping. In other embodiments, artificial lighting may be used for cultivation. The incorporation of lightweight, durable materials such as Low-Density Polyethylene (LDPE) or Polyvinyl Chloride (PVC) for lamination may enhance the efficiency of the system 100 by reducing wear and maintenance demands, further cutting operational energy consumption.
[0062] Additionally, the vertical orientation of the biofilm panels 200 may optimize space usage, making the photobioreactor/film-based reactor 160 particularly suitable for areas with limited space availability. The compact design allows for maximization of surface area over which the photosynthetic microorganisms are cultivated in a given space/area, addressing the challenge of space constraints in industrial and urban settings.
[0063] The photobioreactor/film-based reactor 160 may offer easy installation and maintenance. The modular design of the biofilm panels 200, supported by the one or more (steel) rods 206 and stitched edges, ensures straightforward assembly and disassembly. This modularity simplifies cleaning, substrate 202 replacement, scaling, and/or maintenance. Moreover, the mechanical scraper system for harvesting microbial biomass is adjustable and gentle, ensuring efficient operation without damaging the substrate 202, further reducing labour and maintenance costs.
[0064] The photobioreactor/film-based reactor 160 supports a large-scale carbon capture system for cultivating photosynthetic microorganisms, and biomass production offers a sustainable and efficient approach to reduce carbon emissions while producing valuable byproducts.
[0065] In summary, the biofilm-based panel design for the photobioreactor 160 is a cost-efficient, energy-saving, space-conserving, and user-friendly solution for sustainable carbon capture and biomass production, making it an ideal choice for industrial and environmental applications. By leveraging the natural properties of fabrics and optimizing the design for microorganism growth, the proposed biofilm-based panel design contributes to the development of more efficient and environmentally friendly carbon capture technologies.
[0066] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE PRESENT DISCLOSURE
[0067] The present disclosure provides a biofilm panel for cultivating photosynthetic microorganisms for direct air carbon dioxide sequestration that is optimized for efficiency, cost, easy maintenance, scalability, space requirements, and suitability.
[0068] The present disclosure provides a biofilm panel, which is designed to be simple and lightweight, occupying less space compared to traditional suspension-based photobioreactor systems, thereby making the biofilm-based panel feasible for large-scale operations without requiring enormous areas.
[0069] The present disclosure provides the biofilm panel with a substrate made of materials that improve adherence and growth of photosynthetic microorganisms, leading to higher productivity and better carbon capture efficiency.
[0070] The present disclosure provides the biofilm panel design with a laminated substrated, making it durable and capable of withstanding continuous fluid flow, ensuring long-term usability.
, Claims:1. A biofilm panel (200) for a photobioreactor, comprising:
a substrate (202) comprises a fabric, wherein the substrate (202) is laminated with a lamination material on at least one side thereof;
a support assembly (204) comprising one or more rods (206) configured to support the substrate (202) for vertical hanging, wherein the substrate (202) is assembled to form a loop around the one or more rods (206); wherein the substrate (202) is configured to allow photosynthetic microorganisms to adhere thereto and grow.
2. The biofilm panel (200) as claimed in claim 1, wherein the fabric is any one of or a combination of: jute or cotton.
3. The biofilm panel (200) as claimed in claim 1, wherein the lamination material is selected from any one of: a raxine, a Low-Density Polyethylene (LDPE), a Polyvinyl Chloride (PVC), a coated fabric.
4. The biofilm panel (200) as claimed in claim 1, wherein the support assembly (204) is made of a steel.
5. The biofilm panel (200) of claim 1, wherein the substrate (202) has a Grams Per Square Meter (GSM) range of 100-400, and wherein the fabric has a plain weave or a cross weave.
6. The biofilm panel (200) as claimed in claim 1, wherein the fabric has an End Per Inch (EPI) range of 14-200 and a Pick Per Inch (PPI) range of 14-200.
7. The biofilm panel (200) as claimed in claim 1, wherein a culture of the photosynthetic microorganisms is circulated across a surface of the substrate (202) by a fluid flow unit (208), enabling the culture to adhere to at least one or more grooves of the substrate (202) and proliferate on the surface of the substrate (202).
8. The biofilm panel (200) as claimed in claim 1, wherein the one or more grooves of the substrate (202) are configured to retain fluid flowed over the substrate (202), facilitating the adhesion of the photosynthetic microorganisms to the one or more grooves.
9. The biofilm panel (200) as claimed in claim 1, wherein the substrate (202) comprises a first attachment means (212) and a second attachment means (214), wherein the first attachment means (212) is configured to secure one or more vertical edges of the substrate (202) to provide stability during fluid flow over the substrate (202), and the second attachment means (214) is configured to secure one or more horizontal edges of the substrate (202) with the one or more rods (206) of the support assembly (204).
10. A photobioreactor (100), comprising:
one or more biofilm panels (200), wherein each of the biofilm panel (200) comprises a substrate (202) comprising a fabric whereon the photosynthetic microorganisms adhere to and grow;
a fluid flow unit (208) comprising a fluid flow pipe (216) positioned above the one or more biofilm panels (200) to distribute a fluid evenly over the substrate (202) of the one or more biofilm panels, the fluid being circulated through the fluid flow pipe (216) by a pump (135) in a holding tank (110); and
a bottom tray (210) positioned below the one or more biofilm panels (200) to collect the fluid flowed thereover, wherein the bottom tray (210) is connected to the fluid flow unit (208) to facilitate the recirculation of the fluid collected from the substrate (202) of the one or more biofilm panels (200).