With automation technology, biomass can be cultivated in a closed cycle in a resource-saving way and on a large scale. Everything that is currently produced from crude oil creating carbon dioxide (CO2) emissions can also be obtained sustainably from algae. They are described as small planet protectors because they absorb ten times more CO2 than land plants. This value can be increased by a factor of ten through automated cultivation in bioreactors The biomass obtained can be used in the chemical, food and pharmaceutical industries.
In 2022, Festo presented its bioreactor for the automated cultivation of algae with the PhotoBionicCell project. This year, the team is going even further with the BionicCellFactory, demonstrating a holistic bioprocess – from the optimised cultivation of the algae on a large scale with continuous monitoring and analysis through to harvesting and the further processing and refinement of the various components.
The BionicCellFactory is divided into five modules in which nature and technology coalesce in different ways. In doing so, the cell factory is a tool for the biological transformation moving towards an environmentally friendly circular economy.
- Module 1: CO2 collection: binding CO2 from the air
- Module 2: Analysis: monitoring cells using quantum sensors and AI
- Module 3: Cultivation – controlled growth through automation
- Module 4: Harvest: harvesting the algae using a centrifuge
- Module 5: Enzymatic transformation: extraction and further processing of cell components
A CPX-E controller from Festo controls each module. This means that the five process steps can be put into operation both in combination and separately and can be replaced in the event of production changes. Using dashboards on the respective control panel, experts can monitor and modify individual parameters of the process steps. Data exchange between the modules takes place via OPC UA and enables efficient control of the entire BionicCellFactory.
As a model factory, the BionicCellFactory is said to be the universal blueprint for holistic production systems of the future. With the help of the Festo automation technology, it can be scaled to any size. In order to meet future demand for renewable raw materials, bioreactors with a capacity of several thousand litres are needed. Expertise in process automation is required to ensure that the plants can reliably produce the desired quantities of biomass.
Hannover Messe 2023 is taking place in the Hanover Fairground in Germany from 16-23 April.