BTBioTwin/Clone

Algae PHA / PHB pipeline

Photobioreactor cultivation through solvent-free PHA extraction to melt-spun biopolymer fibre. Every stage is a deterministic mass balance; change a setpoint and the twin recomputes.

Fibre per cycle

419.98 kg

7299.68 kg / yr

CO₂ fixed

3251.18 kg

1.83 kg CO₂ / kg DW

Energy intensity

5889.98 kWh

11.5 kWh / kg polymer

Gross margin

$-6272.16

revenue $3527.84 − opex $9800

Tenacity (model)

12.54 cN/dtex

PHB melt-spun estimate

Cycles / year

17.38

21-day cycle

Mass balance

  1. 01Photobioreactor cultivation
    1,890 kg DW

    18 g/m²/d × 5000 m² × 21 d

  2. 02Harvest & dewatering
    1,776.6 kg DW

    DAF + centrifuge, 6% loss

  3. 03PHA accumulation
    746.17 kg

    42% of dry weight

  4. 04Solvent-free extraction
    582.01 kg crude

    78% recovery

  5. 05Purification / pelletising
    512.17 kg PHB

    88% conversion

  6. 06Melt spinning → fibre
    419.98 kg fibre

    82% spinning yield

Model notes

  • Biomass = area × areal productivity × cycle days, minus 6% harvest loss (DAF + centrifugation).
  • Carbon fixation assumed at 1.83 kg CO₂ per kg dry biomass (Redfield-derived stoichiometry).
  • Tenacity proxy: 0.18·PHA% + 0.09·spinning yield − 2.4, valid for melt-spun PHB monofilament.