Design principles of photo-bioreactors for cultivation of microalgae

A Holistic Approach to Managing Microalgae for Biofuel Applications

Microalgae contribute up to 60% of the oxygen content in the Earth’s atmosphere by absorbing carbon dioxide and releasing oxygen during photosynthesis. Microalgae are abundantly available in the natural environment, thanks to their ability to survive and grow rapidly under harsh and inhospitable conditions. Microalgal cultivation is environmentally friendly because the microalgal biomass can be utilized for the productions of biofuels, food and feed supplements, pharmaceuticals, nutraceuticals, and cosmetics. The cultivation of microalgal also can complement approaches like carbon dioxide sequestration and bioremediation of wastewaters, thereby addressing the serious environmental concerns. This review focuses on the factors affecting microalgal cultures, techniques adapted to obtain high-density microalgal cultures in photobioreactors, and the conversion of microalgal biomass into biofuels. The applications of microalgae in carbon dioxide sequestration and phycoremediation of wastewater are also discussed.

Resource Recovery from Wastewater by Biological Technologies: Opportunities, Challenges, and Prospects

Limits in resource availability are driving a change in current societal production systems, changing the focus from residues treatment, such as wastewater treatment, toward resource recovery. Biotechnological processes offer an economic and versatile way to concentrate and transform resources from waste/wastewater into valuable products, which is a prerequisite for the technological development of a cradle-to-cradle bio-based economy. This review identifies emerging technologies that enable resource recovery across the wastewater treatment cycle. As such, bioenergy in the form of biohydrogen (by photo and dark fermentation processes) and biogas (during anaerobic digestion processes) have been classic targets, whereby, direct transformation of lipidic biomass into biodiesel also gained attention. This concept is similar to previous biofuel concepts, but more sustainable, as third generation biofuels and other resources can be produced from waste biomass. The production of high value biopolymers (e.g., for bioplastics manufacturing) from organic acids, hydrogen, and methane is another option for carbon recovery. The recovery of carbon and nutrients can be achieved by organic fertilizer production, or single cell protein generation (depending on the source) which may be utilized as feed, feed additives, next generation fertilizers, or even as probiotics. Additionlly, chemical oxidation-reduction and bioelectrochemical systems can recover inorganics or synthesize organic products beyond the natural microbial metabolism. Anticipating the next generation of wastewater treatment plants driven by biological recovery technologies, this review is focused on the generation and re-synthesis of energetic resources and key resources to be recycled as raw materials in a cradle-to-cradle economy concept.

Towards microalgal triglycerides in the commodity markets

BACKGROUND

Microalgal triglycerides (TAGs) hold great promise as sustainable feedstock for commodity industries. However, to determine research priorities and support business decisions, solid techno-economic studies are essential. Here, we present a techno-economic analysis of two-step TAG production (growth reactors are operated in continuous mode such that multiple batch-operated stress reactors are inoculated and harvested sequentially) for a 100-ha plant in southern Spain using vertically stacked tubular photobioreactors. The base case is established with outdoor pilot-scale data and based on current process technology.

RESULTS

For the base case, production costs of 6.7 € per kg of biomass containing 24% TAG (w/w) were found. Several scenarios with reduced production costs were then presented based on the latest biological and technological advances. For instance, much effort should focus on increasing the photosynthetic efficiency during the stress and growth phases, as this is the most influential parameter on production costs (30 and 14% cost reduction from base case). Next, biological and technological solutions should be implemented for a reduction in cooling requirements (10 and 4.5% cost reduction from base case when active cooling is avoided and cooling setpoint is increased, respectively). When implementing all the suggested improvements, production costs can be decreased to 3.3 € per kg of biomass containing 60% TAG (w/w) within the next 8 years.

CONCLUSIONS

With our techno-economic analysis, we indicated a roadmap for a substantial cost reduction. However, microalgal TAGs are not yet cost efficient when compared to their present market value. Cost-competiveness strictly relies on the valorization of the whole biomass components and on cheaper PBR designs (e.g. plastic film flat panels). In particular, further research should focus on the development and commercialization of PBRs where active cooling is avoided and stable operating temperatures are maintained by the water basin in which the reactor is placed.

Integrating planar waveguides doped with light scattering nanoparticles into a flat-plate photobioreactor to improve light distribution and microalgae growth

Industrially manufactured planar waveguides doped with light scattering nanoparticles, which can dilute and redistribute the intense incident light within microalgae suspension more uniformly, were introduced into a flat-plate photobioreactor (PBR) with a width of 25cm to alleviate the adverse effect of poor light penetrability on microalgae growth. Compared with the flat-plate PBR without waveguides, the illumination surface area per unit volume in the proposed PBR was increased by 10.3 times. During the whole cultivation period, the illuminated volume fractions in the proposed PBR were 21.4-410% higher than those in the flat-plate PBR without waveguides. Consequently, attributed to the optimized light distribution in the proposed PBR, a 220% improvement in biomass production was obtained relative to that in the flat-plate PBR without waveguides. Furthermore, higher light output intensities emitted from the planar waveguide surfaces and increased microalgae growth rates were achieved by decreasing the length of planar waveguides.

Carbon dioxide capture strategies from flue gas using microalgae: a review

Global warming and pollution are the twin crises experienced globally. Biological offset of these crises are gaining importance because of its zero waste production and the ability of the organisms to thrive under extreme or polluted condition. In this context, this review highlights the recent developments in carbon dioxide (CO2) capture from flue gas using microalgae and finding the best microalgal remediation strategy through contrast and comparison of different strategies. Different flue gas microalgal remediation strategies discussed are as follows: (i) Flue gas to CO2 gas segregation using adsorbents for microalgal mitigation, (ii) CO2 separation from flue gas using absorbents and later regeneration for microalgal mitigation, (iii) Flue gas to liquid conversion for direct microalgal mitigation, and (iv) direct flue gas mitigation using microalgae. This work also studies the economic feasibility of microalgal production. The study discloses that the direct convening of flue gas with high carbon dioxide content, into microalgal system is cost-effective.

Domestic wastewater treatment with purple phototrophic bacteria using a novel continuous photo anaerobic membrane bioreactor

A key future challenge of domestic wastewater treatment is nutrient recovery while still achieving acceptable discharge limits. Nutrient partitioning using purple phototrophic bacteria (PPB) has the potential to biologically concentrate nutrients through growth. This study evaluates the use of PPB in a continuous photo-anaerobic membrane bioreactor (PAnMBR) for simultaneous organics and nutrient removal from domestic wastewater. This process could continuously treat domestic wastewater to discharge limits (<50 mgCOD L(-1), 5 mgN L(-1), 1.0 mgP L(-1)). Approximately 6.4 ± 1.3 gNH4-N and 1.1 ± 0.2 gPO4-P for every 100 gSCOD were removed at a hydraulic retention time of 8-24 h and volumetric loading rates of 0.8-2.5 COD kg m(3) d(-1). Thus, a minimum of 200 mg L(-1) of ethanol (to provide soluble COD) was required to achieve these discharge limits. Microbial community through sequencing indicated dominance of >60% of PPB, though the PPB community was highly variable. The outcomes from the current work demonstrate the potential of PPB for continuous domestic (and possibly industrial) wastewater treatment and nutrient recovery. Technical challenges include the in situ COD supply in a continuous reactor system, as well as efficient light delivery. Addition of external (agricultural or fossil) derived organics is not financially nor environmentally justified, and carbon needs to be sourced internally from the biomass itself to enable this technology. Reduced energy consumption for lighting is technically feasible, and needs to be addressed as a key objective in scaleup.

Optimization of carbon dioxide supply in raceway reactors: Influence of carbon dioxide molar fraction and gas flow rate

Influence of CO2 composition and gas flow rate to control pH in a pilot-scale raceway producing Scenedesmus sp. was studied. Light and temperature determined the biomass productivity whereas neither the CO2 molar fraction nor the gas flow rate used influenced it; because pH was always controlled and carbon limitation did not take place. The CO2 molar fraction and the gas flow rate influenced carbon loss in the system. At low CO2 molar fraction (2-6%) or gas flow rate (75-100l·min(-1)) the carbon efficiency in the sump was higher than 95%, 85% of the injected carbon being transformed into biomass. Conversely, at high CO2 molar fraction (14%) or gas flow rate (150l·min(-1)) the carbon efficiency in the sump was lower than 67%, 32% of the carbon being fixed as biomass. Analysis here reported allows the pH control to be optimized and production costs to be reduced by optimizing CO2 efficiency.

Coupling a simple irradiance description to a mechanistic growth model to predict algal production in industrial-scale solar-powered photobioreactors

Various innovative photobioreactor designs have been proposed to increase production of algae-derived biomass. Computer models are often employed to test these designs prior to construction. In the drive to optimise conversion of light energy to biomass, efforts to model the profile of irradiance levels within a microalgal culture can lead to highly complex descriptions which are computationally demanding. However, there is a risk that this effort is wasted if such optic models are coupled to overly simplified descriptions of algal physiology. Here we demonstrate that a suitable description of microalgal physiology is of primary significance for modelling algal production in photobioreactors. For the first time, we combine a new and computationally inexpensive model of irradiance to a mechanistic description of algal growth and test its applicability to modelling biofuel production in an advanced photobioreactor system. We confirm the adequacy of our approach by comparing the predictions of the model against published experimental data collected over a 2 ½-year period and demonstrate the effectiveness of the mechanistic model in predicting long-term production rates of bulk biomass and biofuel feedstock components at a commercially relevant scale. Our results suggest that much of the detail captured in more complicated irradiance models is indeed wasted as the critical limiting procedure is the physiological description of the conversion of light energy to biomass.

Breathable waveguides for combined light and CO2 delivery to microalgae

Suboptimal light and chemical distribution (CO2, O2) in photobioreactors hinder phototrophic microalgal productivity and prevent economically scalable production of biofuels and bioproducts. Current strategies that improve illumination in reactors negatively impact chemical distribution, and vice versa. In this work, an integrated illumination and aeration approach is demonstrated using a gas-permeable planar waveguide that enables combined light and chemical distribution. An optically transparent cellulose acetate butyrate (CAB) slab is used to supply both light and CO2 at various source concentrations to cyanobacteria. The breathable waveguide architecture is capable of cultivating microalgae with over double the growth as achieved with impermeable waveguides.

Enhancement of microalgae production by embedding hollow light guides to a flat-plate photobioreactor

To offset the adverse effects of light attenuation on microalgae growth, hollow polymethyl methacrylate (PMMA) tubes were embedded into a flat-plate photobioreactor (PBR) as light guides. In this way, a fraction of incident light could be transmitted and emitted to the interior of the PBR, providing a secondary light source for cells in light-deficient regions. The average light intensity of interior regions 3-6cm from surfaces with 70μmolm(-2)s(-1) incident light was enhanced 2-6.5 times after 3.5days cultivation, resulting in a 23.42% increase in biomass production to that cultivated in PBR without PMMA tubes. The photosynthetic efficiency of microalgae in the proposed PBR was increased to 12.52%. Moreover, the installation of hollow PMMA tubes induced turbulent flow in the microalgae suspension, promoting microalgae suspension mixing. However, the enhanced biomass production was mainly attributed to the optimized light distribution in the PBR.

Flashing light in microalgae biotechnology

Flashing light can enhance photosynthesis and improve the quality and quantity of microalgal biomass, as it can increase the products of interest by magnitudes. Therefore, the integration of flashing light effect into microalgal cultivation systems should be considered. However, microalgae require a balanced mix of the light/dark cycle for higher growth rates, and respond to light intensity differently according to the pigments acquired or lost during the growth. This review highlights recently published results on flashing light effect on microalgae and its applications in biotechnology, as well as the recently developed bioreactors designed to fulfill this effect. It also discusses how this knowledge can be applied in selecting the optimal light frequencies and intensities with specific technical properties for increasing biomass production and/or the yield of the chemicals of interest by microalgae belonging to different genera.

Microalgal TAG production strategies: why batch beats repeated-batch

BACKGROUND

For a commercially feasible microalgal triglyceride (TAG) production, high TAG productivities are required. The operational strategy affects TAG productivity but a systematic comparison between different strategies is lacking. For this, physiological responses of Nannochloropsis sp. to nitrogen (N) starvation and N-rich medium replenishment were studied in lab-scale batch and repeated-batch (part of the culture is periodically harvested and N-rich medium is re-supplied) cultivations under continuous light, and condensed into a mechanistic model.

RESULTS

The model, which successfully described both strategies, was used to identify potential improvements for both batch and repeated-batch and compare the two strategies on optimized TAG yields on light (amount of TAGs produced per mol of supplied PAR photons). TAG yields on light, for batch, from 0.12 (base case at high light) to 0.49 g molph (-1) (at low light and with improved strain) and, for repeated-batch, from 0.07 (base case at high light) to 0.39 g molph (-1) (at low light with improved strain and optimized repeated-batch settings). The base case yields are in line with the yields observed in current state-of-the-art outdoor TAG production.

CONCLUSIONS

For continuous light, an optimized batch process will always result in higher TAG yield on light compared to an optimized repeated-batch process. This is mainly because repeated-batch cycles start with N-starved cells. Their reduced photosynthetic capacity leads to inefficient light use during the regrowth phase which results in lower overall TAG yields compared to a batch process.

Design and construction of a photobioreactor for hydrogen production, including status in the field

Several species of microalgae and phototrophic bacteria are able to produce hydrogen under certain conditions. A range of different photobioreactor systems have been used by different research groups for lab-scale hydrogen production experiments, and some few attempts have been made to upscale the hydrogen production process. Even though a photobioreactor system for hydrogen production does require special construction properties (e.g., hydrogen tight, mixing by other means than bubbling with air), only very few attempts have been made to design photobioreactors specifically for the purpose of hydrogen production. We have constructed a flat panel photobioreactor system that can be used in two modes: either for the cultivation of phototrophic microorganisms (upright and bubbling) or for the production of hydrogen or other anaerobic products (mixing by "rocking motion"). Special emphasis has been taken to avoid any hydrogen leakages, both by means of constructional and material choices. The flat plate photobioreactor system is controlled by a custom-built control system that can log and control temperature, pH, and optical density and additionally log the amount of produced gas and dissolved oxygen concentration. This paper summarizes the status in the field of photobioreactors for hydrogen production and describes in detail the design and construction of a purpose-built flat panel photobioreactor system, optimized for hydrogen production in terms of structural functionality, durability, performance, and selection of materials. The motivations for the choices made during the design process and advantages/disadvantages of previous designs are discussed.

Installation of flow deflectors and wing baffles to reduce dead zone and enhance flashing light effect in an open raceway pond

To reduce the dead zone and enhance the flashing light effect, a novel open raceway pond with flow deflectors and wing baffles was developed. The hydrodynamics and light characteristics in the novel open raceway pond were investigated using computational fluid dynamics. Results showed that, compared with the control pond, pressure loss in the flow channel of the pond with optimized flow deflectors decreased by 14.58%, average fluid velocity increased by 26.89% and dead zone decreased by 60.42%. With wing baffles built into the raceway pond, significant swirling flow was produced. Moreover, the period of average L/D cycle was shortened. In outdoor cultivation of freshwater Chlorella sp., the biomass concentration of Chlorella sp. cultivated in the raceway pond with wing baffles was 30.11% higher than that of the control pond.

Integrated hollow fiber membranes for gas delivery into optical waveguide based photobioreactors

Compact algal reactors are presented with: (1) closely stacked layers of waveguides to decrease light-path to enable larger optimal light-zones; (2) waveguides containing scatterers to uniformly distribute light; and (3) hollow fiber membranes to reduce energy required for gas transfer. The reactors are optimized by characterizing the aeration of different gases through hollow fiber membranes and characterizing light intensities at different culture densities. Close to 65% improvement in plateau peak productivities was achieved under low light-intensity growth experiments while maintaining 90% average/peak productivity output during 7-h light cycles. With associated mixing costs of ∼ 1 mW/L, several magnitudes smaller than closed photobioreactors, a twofold increase is realized in growth ramp rates with carbonated gas streams under high light intensities, and close to 20% output improvement across light intensities in reactors loaded with high density cultures.

Dynamic modelling of high biomass density cultivation and biohydrogen production in different scales of flat plate photobioreactors

This paper investigates the scaling‐up of cyanobacterial biomass cultivation and biohydrogen production from laboratory to industrial scale. Two main aspects are investigated and presented, which to the best of our knowledge have never been addressed, namely the construction of an accurate dynamic model to simulate cyanobacterial photo‐heterotrophic growth and biohydrogen production and the prediction of the maximum biomass and hydrogen production in different scales of photobioreactors. To achieve the current goals, experimental data obtained from a laboratory experimental setup are fitted by a dynamic model. Based on the current model, two key original findings are made in this work. First, it is found that selecting low‐chlorophyll mutants is an efficient way to increase both biomass concentration and hydrogen production particularly in a large scale photobioreactor. Second, the current work proposes that the width of industrial scale photobioreactors should not exceed 0.20 m for biomass cultivation and 0.05 m for biohydrogen production, as severe light attenuation can be induced in the reactor beyond this threshold. Biotechnol. Bioeng. 2015;112: 2429–2438. © 2015 The Authors. Biotechnology and Bioengineering Published by Wiley Peiodicals, Inc.

LED light stress induced biomass and fatty acid production in microalgal biosystem, Acutodesmus obliquus

Microbial algal system can serve as a potential source for the production of much high value bioproducts and biofuels. The quality and intensity of light are the key elements to optimize the production of algal biomass and fatty acid contents. This study presents the effect of differential LED flashing light conditions on the growth of microalgae, Acutodesmus obliquus. The induced light stress was optimized for its biomass and fatty acid content. The microalgae are exposed to various frequency of intermittent LED flashing light (blue and red lights) at three different phases in the 18 day cell growth (log, lag and stationary phase). The frequency of light flashing rate was adjusted to 120, 10, 5, 3.75, and 1 times per min. The effect of light stress on growth and fatty acids composition of A. obliquus induced an increase in algae growth and fatty acid production. Different optimal timing for light stress was subjected to elucidate the effect of light stress on algae growth and fatty acid production. The results showed an increase in the algae growth (1.2mg/L of chl a content) under light stress condition at FT10 (flashing time, 10 times per min) from the initial day (log phase) compared with the control experiment (0.4 mg/L of chl a content). However, the total fatty acids (71 mg/g) and volumetric FAME production (9.4 ml/l) level was found to be significant under FT5 (flashing time, 5 times per min), adopting flashing light from day 10 (stationary phase). TEM studies also revealed the deposition of lipid to be largest in the 18 day old cells under flashing light (FT5) condition, representing maximum accumulation of lipids bodies (up to 770 nm diameter in particle size) occupying approximately 42% of the total area of the cell.

Surface physicochemical properties of selected single and mixed cultures of microalgae and cyanobacteria and their relationship with sedimentation kinetics

Background

Microalgae are photosynthetic microorganisms presenting a diversity of biotechnological applications. However, microalgal cultivation systems are not energetically and economically feasible. Possible strategies that can be applied to improve the feasibility of microalgal production include biofouling control in photobioreactors, the use of attached growth systems and bioflocculation. These processes are ruled by surface physicochemical properties. Accordingly, the surface physicochemical properties of Chlorella vulgaris, Pseudokirchneriella subcapitata, Synechocystis salina and Microcystis aeruginosa were determined through contact angle and zeta potential measurements. Additionally, mixed cultures of the selected microorganisms were performed. Sedimentation kinetics of the studied cultures was also evaluated to understand how surface physicochemical properties influence microalgal recovery.

Results

All studied microorganisms, except S. salina, presented a hydrophilic surface. The co-culture of S. salina with the other studied microorganisms resulted in a more hydrophobic algal suspension. Regarding zeta potential determinations, all studied suspensions presented a negatively charged surface (approximately -40.8 ± 4.4 mV). Sedimentation experiments have shown that all microalgal suspensions presented low microalgal recovery efficiencies. However, a negative linear relationship between microalgal removal percentage and free energy of hydrophobic interaction was obtained.

Conclusions

The evidence of a relationship between microalgal removal percentage and free energy of hydrophobic interaction demonstrates the importance of surface physicochemical properties on microalgal settling. However, the low recovery efficiencies achieved, as well as the high net zeta potential values determined, indicate that another factor to consider in microalgal settling is the ionic strength of the culture medium, which play an important role in suspensions’ stability.

Continuous background light significantly increases flashing-light enhancement of photosynthesis and growth of microalgae

Under specific conditions, flashing light enhances the photosynthesis rate in comparison to continuous illumination. Here we show that a combination of flashing light and continuous background light with the same integrated photon dose as continuous or flashing light alone can be used to significantly enhance photosynthesis and increase microalgae growth. To test this hypothesis, the green microalga Dunaliella salina was exposed to three different light regimes: continuous light, flashing light, and concomitant application of both. Algal growth was compared under three different integrated light quantities; low, intermediate, and moderately high. Under the combined light regime, there was a substantial increase in all algal growth parameters, with an enhanced photosynthesis rate, within 3days. Our strategy demonstrates a hitherto undescribed significant increase in photosynthesis and algal growth rates, which is beyond the increase by flashing light alone.

Prospects of geothermal water Use in cultivation of Spirulina

Spirulina has been studied due to its commercial importance as a source of essential amino acids, protein, vitamins, fatty acids etc. Most of the culture systems in use today are open ponds. The new approach proposed in this paper is to use the geothermal water as a medium for microalgae cultivation. Poland has beneficial conditions for wide geothermal use, as one of the environmentally friendly and sustainable renewable energy sources. In the planned research, geothermal water could be used to prepare microalgal culture medium, to heat greenhouses with bioreactors used for the growth of Spirulina, to dry the obtained biomass, as well as to heat the ground in foil tunnels. Using geothermal water gives the possibility to produce algae in open ponds covered with greenhouses and to cultivate plants during winter. The obtained algae can be used for the production of algal bio-products (e.g. homogenates), having the potential application in plant cultivation.

Modelling of Microalgae Culture Systems with Applications to Control and Optimization

Mathematical modeling is becoming ever more important to assess the potential, guide the design, and enable the efficient operation and control of industrial-scale microalgae culture systems (MCS). The development of overall, inherently multiphysics, models involves coupling separate submodels of (i) the intrinsic biological properties, including growth, decay, and biosynthesis as well as the effect of light and temperature on these processes, and (ii) the physical properties, such as the hydrodynamics, light attenuation, and temperature in the culture medium. When considering high-density microalgae culture, in particular, the coupling between biology and physics becomes critical. This chapter reviews existing models, with a particular focus on the Droop model, which is a precursor model, and it highlights the structure common to many microalgae growth models. It summarizes the main developments and difficulties towards multiphysics models of MCS as well as applications of these models for monitoring, control, and optimization purposes.

Monitoring of Microalgal Processes

Process monitoring, which can be defined as the measurement of process variables with the smallest possible delay, is combined with process models to form the basis for successful process control. Minimizing the measurement delay leads inevitably to employing online, in situ sensors where possible, preferably using noninvasive measurement methods with stable, low-cost sensors. Microalgal processes have similarities to traditional bioprocesses but also have unique monitoring requirements. In general, variables to be monitored in microalgal processes can be categorized as physical, chemical, and biological, and they are measured in gaseous, liquid, and solid (biological) phases. Physical and chemical process variables can be usually monitored online using standard industrial sensors. The monitoring of biological process variables, however, relies mostly on sensors developed and validated using laboratory-scale systems or uses offline methods because of difficulties in developing suitable online sensors. Here, we review current technologies for online, in situ monitoring of all types of process parameters of microalgal cultivations, with a focus on monitoring of biological parameters. We discuss newly introduced methods for measuring biological parameters that could be possibly adapted for routine online use, should be preferably noninvasive, and are based on approaches that have been proven in other bioprocesses. New sensor types for measuring physicochemical parameters using optical methods or ion-specific field effect transistor (ISFET) sensors are also discussed. Reviewed methods with online implementation or online potential include measurement of irradiance, biomass concentration by optical density and image analysis, cell count, chlorophyll fluorescence, growth rate, lipid concentration by infrared spectrophotometry, dielectric scattering, and nuclear magnetic resonance. Future perspectives are discussed, especially in the field of image analysis using in situ microscopy, infrared spectrophotometry, and software sensor systems.