Model-supported phototrophic growth studies with Scenedesmus obtusiusculus in a flat-plate photobioreactor

Lab-scale photobioreactor systems: principles, applications, and scalability

Phototrophic microorganisms that convert carbon dioxide are being explored for their capacity to solve different environmental issues and produce bioactive compounds for human therapeutics and as food additives. Full-scale phototrophic cultivation of microalgae and cyanobacteria can be done in open ponds or closed photobioreactor systems, which have a broad range of volumes. This review focuses on laboratory-scale photobioreactors and their different designs. Illuminated microtiter plates and microfluidic devices offer an option for automated high-throughput studies with microalgae. Illuminated shake flasks are used for simple uncontrolled batch studies. The application of illuminated bubble column reactors strongly emphasizes homogenous gas distribution, while illuminated flat plate bioreactors offer high and uniform light input. Illuminated stirred-tank bioreactors facilitate the application of very well-defined reaction conditions. Closed tubular photobioreactors as well as open photobioreactors like small-scale raceway ponds and thin-layer cascades are applied as scale-down models of the respective large-scale bioreactors. A few other less common designs such as illuminated plastic bags or aquarium tanks are also used mainly because of their relatively low cost, but up-scaling of these designs is challenging with additional light-driven issues. Finally, this review covers recommendations on the criteria for photobioreactor selection and operation while up-scaling of phototrophic bioprocesses with microalgae or cyanobacteria.

Effective Prediction of Monthly Heat Transfer Characteristics in a Thin-Layer Cascade Reactor Subjected to Outdoor Conditions

Algal biofuels are intriguingly a renewable energy source that could partially substitute fossil fuels, but further research is required to optimise the growth parameters and establish competitive large-scale cultivation systems. Algal growth is directly dependent on momentum, heat, and mass transfer within the photobioreactor and environmental conditions. Therefore, in this computational study, the heat transfer between the thin-layer cascade (TLC) reactor and its surrounding was reported based on static (location and reactor geometry) and dynamic (air temperature, solar irradiance, and wind velocity) parameters. The resulting model was validated using experimental data. The Nusselt number and the monthly average water temperature were computed to investigate the heat transfer phenomena between the TLC reactor and atmosphere. In addition, a novel corelation was used to estimate the evaporative losses from the TLC reactor. The effect of geometric properties (inclination angle of the reactor, water depth, and channel width) was evaluated on heat transfer. Results showed that heat transfer rate and the optimum water temperature for algal growth were significantly affected by hydrodynamics, environmental conditions, and reactor design. Water temperature decreased with the increase in channel width, water depth, and slope angle of the reactor. Furthermore, algal productivity declined with the increase in the amount of evaporated water.

Process Engineering Aspects for the Microbial Conversion of C1 Gases

Industrially applied bioprocesses for the reduction of C1 gases (CO₂ and/or CO) are based in particular on (syn)gas fermentation with acetogenic bacteria and on photobioprocesses with microalgae. In each case, process engineering characteristics of the autotrophic microorganisms are specified and process engineering aspects for improving gas and electron supply are summarized before suitable bioreactor configurations are discussed for the production of organic products under given economic constraints. Additionally, requirements for the purity of C1 gases are summarized briefly. Finally, similarities and differences in microbial CO₂ valorization are depicted comparing gas fermentations with acetogenic bacteria and photobioprocesses with microalgae.

A Newly Designed Automatically Controlled, Sterilizable Flat Panel Photobioreactor for Axenic Algae Culture

In context of the global climate change, microalgae processes are gaining momentum as a biotechnological tool for direct fixation and valorization of greenhouse gases. Algae have the metabolic capacity to photosynthetically convert CO₂ into high value products, such as food additives, under economic boundary conditions. High cost, commercial flat panel gas-lift bioreactors for microalgae cultivation at laboratory scale provide either small volumes or no sterile operation, which limits academic research. This brief report presents initial data for a new type of sterile operating flat panel gas-lift bioreactor with a unique asymmetrical U-shape. It utilizes automatable process control technologies that adhere to industrial standards to enhance data reproducibility and aid industrial scale up. The practicability was demonstrated using a Chlorella sorokiniana cultivation, which showed the typical growth behavior. Due to the sophisticated implemented control engineering technology, pivotal parameters as pH and temperature can be determined within a range of ±0.1 units, which was confirmed experimentally. The new flat panel gas-lift photobioreactor presented in this brief report fills the technology gap at laboratory scale with an autoclavable volume of 7.2 L. Moreover, it is easy to rebuild by means of the hereby provided blueprint, while exhibiting a six-fold cost reduction compared to commercially available flat panel photobioreactors.

Computational Analysis of Dynamic Light Exposure of Unicellular Algal Cells in a Flat-Panel Photobioreactor to Support Light-Induced CO2 Bioprocess Development

Cyanobacterial cell factories trace a vibrant pathway to climate change neutrality and sustainable development owing to their ability to turn carbon dioxide-rich waste into a broad portfolio of renewable compounds, which are deemed valuable in green chemistry cross-sectorial applications. Cell factory design requires to define the optimal operational and cultivation conditions. The paramount parameter in biomass cultivation in photobioreactors is the light intensity since it impacts cellular physiology and productivity. Our modeling framework provides a basis for the predictive control of light-limited, light-saturated, and light-inhibited growth of the Synechocystis sp. PCC 6803 model organism in a flat-panel photobioreactor. The model here presented couples computational fluid dynamics, light transmission, kinetic modeling, and the reconstruction of single cell trajectories in differently irradiated areas of the photobioreactor to relate key physiological parameters to the multi-faceted processes occurring in the cultivation environment. Furthermore, our analysis highlights the need for properly constraining the model with decisive qualitative and quantitative data related to light calibration and light measurements both at the inlet and outlet of the photobioreactor in order to boost the accuracy and extrapolation capabilities of the model.

Synergising biomass growth kinetics and transport mechanisms to simulate light/dark cycle effects on photo-production systems

Light attenuation is a primary challenge limiting the upscaling of photobioreactors for sustainable bio-production. One key to this challenge, is to model and optimise the light/dark cycles so that cells within the dark region can be frequently transferred to the light region for photosynthesis. Therefore, this study proposes the first mechanistic model to integrate the light/dark cycle effects into biomass growth kinetics. This model was initially constructed through theoretical derivation based on the intracellular reaction kinetics, and was subsequently modified by embedding a new parameter, effective light coefficient, to account for the effects of culture mixing. To generate in silico process data, a new multiscale reactive transport modelling strategy was developed to couple fluid dynamics with biomass growth kinetics and light transmission. By comparing against previous experimental and computational studies, the multiscale model shows to be of high accuracy. Based on its simulation result, an original correlation was proposed to link effective light coefficient with photobioreactor gas inflow rate; this has not been done before. The impact of this study is that by using the proposed mechanistic model and correlation, we can easily control and optimise photobioreactor gas inflow rates to alleviate light attenuation and maintain a high biomass growth rate.

Continuous Production of Lipids with Microchloropsis salina in Open Thin-Layer Cascade Photobioreactors on a Pilot Scale

Studies on microalgal lipid production as a sustainable feedstock for biofuels and chemicals are scarce, particularly those on applying open thin-layer cascade (TLC) photobioreactors under dynamic diurnal conditions. Continuous lipid production with Microchloropsis salina was studied in scalable TLC photobioreactors at 50 m2 pilot scale, applying a physically simulated Mediterranean summer climate. A cascade of two serially connected TLC reactors was applied, promoting biomass growth under nutrient-replete conditions in the first reactor, while inducing the accumulation of lipids via nitrogen limitation in the second reactor. Up to 4.1 g L−1 of lipids were continuously produced at productivities of up to 0.27 g L−1 d−1 (1.8 g m2 d−1) at a mean hydraulic residence time of 2.5 d in the first reactor and 20 d in the second reactor. Coupling mass balances with the kinetics of microalgal growth and lipid formation enabled the simulation of phototrophic process performances of M. salina in TLC reactors in batch and continuous operation at the climate conditions studied. This study demonstrates the scalability of continuous microalgal lipid production in TLC reactors with M. salina and provides a TLC reactor model for the realistic simulation of microalgae lipid production processes after re-identification of the model parameters if other microalgae and/or varying climate conditions are applied.

Models of microalgal cultivation for added-value products - A review

Microalgae are considered a promising feedstock for biorefineries given that their chemical composition - rich in carbohydrate and lipid - can be directed towards the co-production of various value-added fuels and chemicals. Production of microalgal biomass for biorefinery purposes requires the identification and establishment of optimal cultivation systems, a crucial yet complicated task due to the numerous factors (e.g. media composition, light, temperature) that simultaneously regulate biomass growth and intracellular composition. Modelling these biological processes, taking into account a single or multiple growth-limiting factors, offers a valuable tool to simulate, design and optimise the dynamics of microalgae cultivation. This review provides an overview of existing models developed to describe microalgal growth processes at the macroscopic scale (also termed black-box models) and discusses their formulation in detail. The black-box kinetic modelling frameworks are compiled into single-factor (6 formulations) and multiple-factor (32 formulations - further divided into non-interactive, additive, and interactive) growth kinetic models, as reported in more than 80 studies, for the prediction of biomass growth as a function of major operational factors such as media composition (e.g. nutrient concentration) and environmental factors (e.g. transient light and temperature). In addition, the review focuses on those models that further account for the production dynamics of two microalgal intracellular products with renowned potential as biorefinery substrates: carbohydrate and lipid molecules. Models of microalgal cultivation dynamics offer a robust engineering tool to understand the natural yet complex responses of microalgae to their growing environment and can help - if used appropriately - to optimise microalgae cultivation and increase the economic viability and sustainability of microalgal systems.

Development of Novel Bioreactor Control Systems Based on Smart Sensors and Actuators

Bioreactors of various forms have been widely used in environmental protection, healthcare, industrial biotechnology, and space exploration. Robust demand in the field stimulated the development of novel designs of bioreactor geometries and process control strategies and the evolution of the physical structure of the control system. After the introduction of digital computers to bioreactor process control, a hierarchical structure control system (HSCS) for bioreactors has become the dominant physical structure, having high efficiency and robustness. However, inherent drawbacks of the HSCS for bioreactors have produced a need for a more consolidated solution of the control system. With the fast progress in sensors, machinery, and information technology, the development of a flat organizational control system (FOCS) for bioreactors based on parallel distributed smart sensors and actuators may provide a more concise solution for process control in bioreactors. Here, we review the evolution of the physical structure of bioreactor control systems and discuss the properties of the novel FOCS for bioreactors and related smart sensors and actuators and their application circumstances, with the hope of further improving the efficiency, robustness, and economics of bioprocess control.

Microalgae and cyanobacteria modeling in water resource recovery facilities: A critical review

Microalgal and cyanobacterial resource recovery systems could significantly advance nutrient recovery from wastewater by achieving effluent nitrogen (N) and phosphorus (P) levels below the current limit of technology. The successful implementation of phytoplankton, however, requires the formulation of process models that balance fidelity and simplicity to accurately simulate dynamic performance in response to environmental conditions. This work synthesizes the range of model structures that have been leveraged for algae and cyanobacteria modeling and core model features that are required to enable reliable process modeling in the context of water resource recovery facilities. Results from an extensive literature review of over 300 published phytoplankton models are presented, with particular attention to similarities with and differences from existing strategies to model chemotrophic wastewater treatment processes (e.g., via the Activated Sludge Models, ASMs). Building on published process models, the core requirements of a model structure for algal and cyanobacterial processes are presented, including detailed recommendations for the prediction of growth (under phototrophic, heterotrophic, and mixotrophic conditions), nutrient uptake, carbon uptake and storage, and respiration.

Potential of Microalgae Carotenoids for Industrial Application

Microalgae cultivation, when compared to the growth of higher plants, presents many advantages such as faster growth, higher biomass productivity, and smaller land area requirement for cultivation. For this reason, microalgae are an alternative platform for carotenoid production when compared to the traditional sources. Currently, commercial microalgae production is not well developed but, fortunately, there are several studies aiming to make the large-scale production feasible by, for example, employing different cultivation systems. This review focuses on the main carotenoids from microalgae, comparing them to the traditional sources, as well as a critical analysis about different microalgae cultivation regimes that are currently available and applicable for carotenoid accumulation. Throughout this review paper, we present relevant information about the main commercial microalgae carotenoid producers; the comparison between carotenoid content from food, vegetables, fruits, and microalgae; and the great importance and impact of these molecule applications, such as in food (nutraceuticals and functional foods), cosmetics and pharmaceutical industries, feed (colorants and additives), and healthcare area. Lastly, the different operating systems applied to these photosynthetic cultivations are critically discussed, and conclusions and perspectives are made concerning the best operating system for acquiring high cell densities and, consequently, high carotenoid accumulation.

A novel mechanistic model for nitrogen removal in algal-bacterial photo sequencing batch reactors

A comprehensive mathematical model was constructed to evaluate the complex substrate and microbial interaction in algal-bacterial photo sequencing batch reactors (PSBR). The kinetics of metabolite, growth and endogenous respiration of ammonia oxidizing bacteria, nitrite oxidizing bacteria and heterotrophic bacteria were coupled to those of microalgae and then embedded into widely-used activated sludge model series. The impact of light intensity was considered for microalgae growth, while the effect of inorganic carbon was considered for each microorganism. The integrated model framework was assessed using experimental data from algal-bacterial consortia performing sidestream nitritation/denitritation. The validity of the model was further evaluated based on dataset from PSBR performing mainstream nitrification. The developed model could satisfactorily capture the dynamics of microbial populations and substrates under different operational conditions (i.e. feeding, carbon dosing and illuminating mode, light intensity, influent ammonium concentration), which might serve as a powerful tool for optimizing the novel algal-bacterial nitrogen removal processes.

Bare Iron Oxide Nanoparticles for Magnetic Harvesting of Microalgae: From Interaction Behavior to Process Realization

Microalgae continue to gain in importance as a bioresource, while their harvesting remains a major challenge at the moment. This study presents findings on microalgae separation using low-cost, easy-to-process bare iron oxide nanoparticles with the additional contribution of the upscaling demonstration of this simple, adhesion-based process. The high affinity of the cell wall for the inorganic surface enables harvesting efficiencies greater than 95% for Scenedesmus ovalternus and Chlorella vulgaris. Successful separation is possible in a broad range of environmental conditions and primarily depends on the nanoparticle-to-microalgae mass ratio, whereas the effect of pH and ionic strength are less significant when the mass ratio is chosen properly. The weakening of ionic concentration profiles at the interphase due to the successive addition of deionized water leads the microalgae to detach from the nanoparticles. The process works efficiently at the liter scale, enabling complete separation of the microalgae from their medium and the separate recovery of all materials (algae, salts, and nanoparticles). The current lack of profitable harvesting processes for microalgae demands innovative approaches to encourage further development. This application of magnetic nanoparticles is an example of the prospects that nanobiotechnology offers for biomass exploitation.