Table of Contents

Background

This project was developed for Zaara Biotech, a company that uses spirulina to produce protein-rich biscuits. To support their production, spirulina needs to be cultivated efficiently, and that’s where the OrgoReactor comes in.

About the Project

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The OrgoReactor is a compact photobioreactor designed for the cultivation of Spirulina, a nutrient-rich microalgae with immense health and environmental benefits. The device incorporates an onboard processor and a memory touch display, allowing users to easily input parameters and control reactor operations. It enables precise regulation of temperature and pH levels, which are vital for optimal Spirulina growth.

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Successfully led a team of five skilled individuals in the challenging task of designing and developing a photobioreactor from scratch.

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The project involves the development of a photobioreactor (PBR) as a part-time project for Zaara Biotech. A PBR is a specialized bioreactor that utilizes a light source to cultivate phototropic microorganisms. The main objective of this project is to design and build a PBR device that can efficiently cultivate these microorganisms by providing them with optimal conditions for growth.

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The device incorporates an onboard processor and a memory touch display, allowing users to input various parameters and control the reactor's operation.

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Capable of controlling the temperature and pH levels of the reactor directly and from any part of the world using IoT.

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Timer function and valve control settings that enable users to customize the operation of the device according to their specific requirements.

Features

The Team

We are Rayan Abdul Gafoor, Abhishankar, Kashyap Krishna, Akshay Jojo, and Jibin Prekash , a team of passionate engineers who collaboratively designed and developed the OrgoReactor from concept to completion.

My Contribution

I led a team of five members in developing the OrgoReactor from scratch, overseeing the entire process from concept to completion. My key responsibilities included electronic design, PCB fabrication, system integration, and debugging , ensuring seamless functionality and reliable performance of the reactor.

Electronics Design

The electronics design of the OrgoReactor was created using EasyEDA, ensuring precise circuit development and component placement. A two-layer PCB was then fabricated through LionCircuits, providing a reliable and compact hardware foundation for the system.

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Main Components

  1. Esp32
  1. Nextion Capacitive Touch Display
  1. pH Sensor
  1. Temperature Sensor
  1. Relay Modules
  1. RTC Module
  1. LED Panel
  1. Buzzer

BOM

ID Name Designator Quantity
1 FMQ-BUZZER2 BUZZER1 1
2 0.22uF Electrolytic Capacitors(860010772002) C1,C5 2
3 0.1uF ceramic capacitor C4,C7 2
4 10uF Electrolytic Capacitors C6 1
5 100nF SMD 0603 Ceramic CAPACITOR C11,C15 2
6 1MΩ SMD 0603 RESISTOR R14 1
7 Zener diode PHC33 D1 1
8 female header pins 1x4 H1,H6,H7,H8,H9 5
9 female header pins 1x6 H2,H4 2
10 Male header pins_1x2 J14,J17,J18,J19,J20,J21,J26,J27,J28,J29,J30,J31,J32,J33,J34,J35 16
11 Male header pins_2x2 J2,J3 2
12 female header pins_1x6 J6,J9,J10,P2 4
13 female header pins_1x5 J7,H3 2
14 Male header pins 1x3 J8,J11,J12,J13,J22,J23,J24,J25 8
15 SLIDING SWITCH SW1,SW2 2
16 DC POWER-JACK Female U2 1
17 ATMEGA2560-16AU U3 1
18 JST 2.54mm male connector [3 Pin] U6,U10,U11,U12,U7,U8 6
19 JST 2.54mm Female connector [3 Pin] 6
20 7805 voltage regulator U9 1
21 AWSCR-16.00MTD-T SMD Y2 1
22 LED Green-0805 SMD LED2,LED6,LED8,LED10,LED11,LED12,LED15,LED16,LED18,LED1,LED3,LED13,LED21 13
23 LED Red -0805 SMD LED7,LED9,LED14,LED17,LED19,LED4,LED5,LED20 8
24 1k  SMD 1206 R1,R2,R20,R21,R22,R23,R24,R25,R12,R26,R27,R28,R29,R30,R31,R32,R33,R34,R15,R18,R36,R11,R19,R37,R16,R17,R35 27
25 4.7k SMD 1206 R3,R4,R5 3
26 10k SMD 1206 R6,R7,R8,R9,R13 5
27 Screw terminal 2 PIN 5.08mm CN1,CN2,CN3,CN4,CN5,CN6 6
28 1N4007 diode D2,D3,D4,D6,D7,D8 6
29 Relay 5v spdt K1,K2,K3,K4,K5,K6 6
30 BC547 NPN Transistor Q6,Q9,Q10,Q4,Q5,Q7 6
31 EL817C SMD Optocouplers U1,U5,U13,U8,U17,U19 6
32 RTC DS3231 U14 1
33 Female Header pins 1x2 J1,J4,J5 3
34 IRF540 MOSFET N-Channel Q1,Q2,Q3 3
35 8 PIN DIP SOCKET U16 1
36 SS36F SMD Schottky diode D5 1
37 HDR-M-2.54_1x15 J15,J16 2
38 PUSHBUTTON 4 PIN DIP 5.08mm U15 1
39 ESP32 DEVKIT V1 DOIT U18 1
40 0.1uF/100nf 50V SMD1206 Electrolytic Capacitors C2,C3,C8 3
41 10k SMD 1206 R10 1
42 EEPROM 24C04N DIP8 IC 1
43 JUMPER SHORT 2.54mm 30
44 CP2102 UART with DTR PIN 1
45 16MHz Crystal OscillatorDIP 1
46 22pF Ceramic Capacitor 50V 2
47 SMPS 1
48 DC POWER-JACK male 1
49 Spacer 8

System Integration