A unique wastewater-to-fuel experiment that began in Daphne is now searching for a full-scale commercial home, with company officials saying Mobile Bay remains a top contender for the expansion. The project, a partnership between Daphne Utilities and technology firm Algae Systems, backed by Japanese engineering giant IHI, has spent roughly two years proving out a process that turns algae and treated wastewater into both drinking water and crude oil.
Company representatives say they are evaluating between 15 and 17 potential sites for the commercial-scale operation, with a decision expected within the next couple of months. A company vice president told reporters he remains hopeful the commercial facility can be located on Mobile Bay itself, citing the region’s unique combination of water access, warm climate, and community support as major assets for the technology.
The process starts small, quite literally, with a single cell of locally sourced algae grown until it reaches sufficient volume. That algae is then mixed with disinfected wastewater inside large floating bags that sit directly on the surface of Mobile Bay, where sunlight and wave action do much of the work. Carbon dioxide scrubbed from the atmosphere is fed to the algae as it grows, a process company officials describe as producing the first carbon-negative fuel ever created.
After roughly four to six days, the algae stops growing and the mixture is pumped ashore, where the algae is separated from the water. The water can then be filtered down to drinking-water quality, while the concentrated algae, once it reaches about 10 percent of the mixture, is fed into a process called hydrothermal liquefaction. Heated to roughly 600 degrees Fahrenheit for just a few minutes, the mixture converts into crude oil that can be refined into standard fuel products.
Company officials say the specialized bags used to hold the algae mixture, made using materials supplied by an athletic apparel manufacturer, are part of what sets the process apart from other algae-to-fuel efforts that have struggled with unfavorable economics. The pilot facility currently operates on about half an acre of bags, handling roughly 40,000 gallons of wastewater treatment daily, and the company has already tested how the design scales up for larger volumes.
The project has also triggered a leadership shuffle at Daphne Utilities. The utility’s general manager is transitioning into a new role as Algae Systems’ vice president of operations and market development, while the assistant general manager is stepping up to lead the utility. Company leaders say a full commercial installation could process a million gallons of wastewater per day or more, representing a significant leap from the pilot’s current scale.
If Mobile Bay is ultimately chosen, the project could position Baldwin County as a hub for an emerging clean-energy technology that converts a persistent environmental challenge, wastewater treatment, into both drinking water and a renewable fuel source.