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

Enhancing high-density microalgae cultivation via exogenous supplementation of biostimulant derived from onion peel waste for sustainable biodiesel production

Microalgae demonstrate significant potential as a source of liquid-based biofuels. However, increasing biomass productivity in existing cultivation systems is a critical prerequisite for their successful integration into large-scale operations. Thus, the current work aimed to accelerate the growth of C. vulgaris via exogenous supplementation of biostimulant derived from onion peel waste. Under the optimal growth conditions, which entailed a biostimulant dosage of 37.5% v/v, a pH of 3, an air flow rate of 0.4 L/min, and a 2% v/v inoculum harvested during the mid-log phase, yielded a maximum biomass concentration of 1.865 g/L. Under the arbitrarily optimized parameters, a comparable growth pattern was evident in the upscaled cultivation of C. vulgaris, underscoring the potential commercial viability of the biostimulant. The biostimulant, characterized through gas chromatography-mass spectrometry (GC-MS) analysis, revealed a composition rich in polyphenolic and organo-sulphur compounds, notably including allyl trisulfide (28.13%), methyl allyl trisulfide (23.04%), and allyl disulfide (20.78%), showcasing potent antioxidant properties. Additionally, microalgae treated with the biostimulant consistently retained their lipid content at 18.44% without any significant reduction. Furthermore, a significant rise in saturated fatty acid (SFA) content was observed, with C16:0 and C18:1 dominating both bench-scale (44.08% and 14.01%) and upscaled (51.12% and 13.07%) microalgae cultures, in contrast to the control group where C18:2 was prevalent. Consequently, SFA contents reached 54.35% and 65.43% in bench-scale and upscaled samples respectively, compared to 33.73% in the control culture. These compositional characteristics align well with the requirements for producing high-quality crude biodiesel.

A custom 3D printed paddlewheel improves growth in flat panel photobioreactor

One of the main challenges with using flat panel photobioreactors for algal growth is uneven mixing and settling of cells in corners, especially when bubbling is the only method used for mixing. In order to improve mixing in our flat panel reactor, we designed a custom paddlewheel. Paddlewheels are frequently used in outdoor algae raceway ponds to improve mixing and we are taking advantage of the same principle for mixing in the reactor. The paddlewheel is easily integrated into our PSI FMT150 1-L flat panel photobioreactor and is printed on a 3D printer using high temperature poly lactic acid (HT-PLA). With the inclusion of an annealing step, the paddlewheel is autoclavable. Addition of the paddlewheel in the reactor minimized cell settling and improved algal growth, as evidenced by a nearly 40% increase in oxygen production rates. Nutrient dispersion and utilization in the culture was also improved as evidenced by a corresponding 38% decrease in CO2 concentration. The paddlewheel device presented here is a cost-effective method for improving algal growth in a flat panel photobioreactor.

Modeling and optimization of biomass productivity of Chlorella vulgaris using response surface methodology, analysis of variance and machine learning for carbon dioxide capture

This study explores bioremediation's effectiveness in reducing carbon emissions through the use of microalgae Chlorella vulgaris, known for capturing carbon dioxide and producing biomass. The impact of temperature and light intensity on productivity and carbon dioxide capture was investigated, and cultivation conditions were optimized in a photobioreactor using response surface methodology (RSM), analysis of variance (ANOVA), and deep neural networks (DNN). The optimal conditions determined were 28.74 °C and 225 μmol/m2/s with RSM, and 29.55 °C and 226.77 μmol/m2/s with DNN, closely aligning with literature values (29 °C and 225 μmol/m2/s). DNN demonstrated superior performance compared to RSM, achieving higher accuracy due to its capacity to process larger datasets using epochs and batches. The research serves as a foundation to further in this field by demonstrating the potential of utilizing diverse mathematical models to optimize bioremediation conditions, and offering valuable insights to improve carbon dioxide capture efficiency in microalgae cultivation.

Photobioreactor configurations in cultivating microalgae biomass for biorefinery

Microalgae, highly prized for their protein, lipid, carbohydrate, phycocyanin, and carotenoid-rich biomass, have garnered significant industrial attention in the context of third-generation (3G) biorefineries, seeking sustainable alternatives to non-renewable resources. Two primarily cultivation methods, open ponds and closed photobioreactors systems, have emerged. Open ponds, favored for their cost-effectiveness in large-scale industrial production, although lacking precise environmental control, contrast with closed photobioreactors, offering controlled conditions and enhanced biomass production at the laboratory scale. However, their high operational costs challenge large-scale deployment. This review comprehensively examines the strength, weakness, and typical designs of both outdoor and indoor microalgae cultivation systems, with an emphasis on their application in terms of biorefinery concept. Additionally, it incorporates techno-economic analyses, providing insights into the financial aspects of microalgae biomass production. These multifaceted insights, encompassing both technological and economic dimensions, are important as the global interest in harnessing microalgae's valuable resources continue to grow.

The Role of Light on the Microalgae Biotechnology: Fundamentals, Technological Approaches, and Sustainability Issues

Light energy directly affects microalgae growth and productivity. Microalgae in natural environments receive light through solar fluxes, and their duration and distribution are highly variable over time. Consequently, microalgae must adjust their photosynthetic processes to avoid photo limitation and photoinhibition and maximize yield. Considering these circumstances, adjusting light capture through artificial lighting in the main culture systems benefits microalgae growth and induces the production of commercially important compounds. In this sense, this review provides a comprehensive study of the role of light in microalgae biotechnology. For this, we present the main fundamentals and reactions of metabolism and metabolic alternatives to regulate photosynthetic conversion in microalgae cells. Light conversions based on natural and artificial systems are compared, mainly demonstrating the impact of solar radiation on natural systems and lighting devices, spectral compositions, periodic modulations, and light fluxes when using artificial lighting systems. The most commonly used photobioreactor design and performance are shown herein, in addition to a more detailed discussion of light-dependent approaches in these photobioreactors. In addition, we present the principal advances in photobioreactor projects, focusing on lighting, through a patent-based analysis to map technological trends. Lastly, sustainability and economic issues in commercializing microalgae products were presented.

Towards industrial biological hydrogen production: a review

Increased production of renewable energy sources is becoming increasingly needed. Amidst other strategies, one promising technology that could help achieve this goal is biological hydrogen production. This technology uses micro-organisms to convert organic matter into hydrogen gas, a clean and versatile fuel that can be used in a wide range of applications. While biohydrogen production is in its early stages, several challenges must be addressed for biological hydrogen production to become a viable commercial solution. From an experimental perspective, the need to improve the efficiency of hydrogen production, the optimization strategy of the microbial consortia, and the reduction in costs associated with the process is still required. From a scale-up perspective, novel strategies (such as modelling and experimental validation) need to be discussed to facilitate this hydrogen production process. Hence, this review considers hydrogen production, not within the framework of a particular production method or technique, but rather outlines the work (bioreactor modes and configurations, modelling, and techno-economic and life cycle assessment) that has been done in the field as a whole. This type of analysis allows for the abstraction of the biohydrogen production technology industrially, giving insights into novel applications, cross-pollination of separate lines of inquiry, and giving a reference point for researchers and industrial developers in the field of biohydrogen production.

A review of microalgae biofilm as an eco-friendly approach to bioplastics, promoting environmental sustainability

In this comprehensive review, we delve into the challenges hindering the large-scale production of microalgae-based bioplastics, primarily focusing on economic feasibility and bioplastic quality. To address these issues, we explore the potential of microalgae biofilm cultivation as a sustainable and highly viable approach for bioplastic production. We present a proposed method for producing bioplastics using microalgae biofilm and evaluate its environmental impact using various tools such as life cycle analysis (LCA), ecological footprint analysis, resource flow analysis, and resource accounting. While pilot-scale and large-scale LCA data are limited, we utilize alternative indicators such as energy efficiency, carbon footprint, materials management, and community acceptance to predict the environmental implications of commercializing microalgae biofilm-based bioplastics. The findings of this study indicate that utilizing microalgae biofilm for bioplastic production offers significant environmental sustainability benefits. The system exhibits low energy requirements and a minimal carbon footprint. Moreover, it has the potential to address the issue of wastewater by utilizing it as a carbon source, thereby mitigating associated problems. However, it is important to acknowledge certain limitations associated with the method proposed in this review. Further research is needed to explore and engineer precise techniques for manipulating microalgae biofilm structure to optimize the accumulation of desired metabolites. This could involve employing chemical triggers, metabolic engineering, and genetic engineering to achieve the intended goals. In conclusion, this review highlights the potential of microalgae biofilm as a viable and sustainable solution for bioplastic production. While acknowledging the advantages, it also emphasizes the need for continued synthetic studies to enhance the efficiency and reliability of this approach. By addressing the identified drawbacks and maximizing the utilization of advanced techniques, we can further harness the potential of microalgae biofilm in contributing to a more environmentally friendly and economically feasible bioplastic industry.

Microalgae and biogas: a boon to energy sector

The global energy generation market immensely depends on fossil fuels which balances our survival on this planet. Energy can be called as the "master element" for our daily needs, starting from household power supply, agricultural purpose, automobile and transportation, industrial workload to economic and research domains. Fuel switching initiatives are being adapted by environmentalist and scientists to bring a novel sustainable source of energy. An environment and renewable alternative to fossil fuels are a must. Over the years, the world has shifted toward generating green fuels immensely. One such potential alternative to fossil fuels are biogases. Being versatile and renewable in nature, it has drawn immense attention globally. Despite having such potentials there exist some major drawbacks which mainly deal with the starting material. One such source for biogases can be microalgae. Microalgae based biogas production can produce huge amount of energy and that has been implemented by many foreign countries and their companies. Despite being in use in many countries, there are issues which needs to be addressed which will overall improve the biogas potential from microalgae even more. This review mainly focuses on generation of biogas from microalgae as a feedstock which are very economical and sustainable in its nature, presenting improvement strategies which can be impended to boost the over biogas sector globally.

Utilizing CO2 in industrial off-gas for microalgae cultivation: considerations and solutions

The utilization of microalgae to treat carbon dioxide (CO₂)-rich industrial off-gas has been suggested as both beneficial for emissions reduction and economically favorable for the production of microalgal products. Common sources of off-gases include coal combustion (2-15% CO₂), cement production (8-15% CO₂), coke production (18-23% CO₂), and ore smelting (6-7% CO₂). However, industrial off-gas also commonly contains other acid gas components [typically nitrogen oxides (NO_X) and sulfur dioxide (SO₂)] and metals that could inhibit microalgae growth and productivity. To utilize industrial off-gas effectively in microalgae cultivation systems, a number of solutions have been proposed to overcome potential inhibitions. These include bioprospecting to identify suitable strains, genetic modification to improve specific cellular characteristics, chemical additions, and bioreactor designs and operating procedures.In this review, results from microalgae experiments related to utilizing off-gas are presented, and the outcomes of different conditions discussed along with potential solutions to resolve limitations associated with the application of off-gas.

Metabolic sink engineering in cyanobacteria: Perspectives and applications

Recent advances in metabolic engineering have made cyanobacteria emerge as promising and attractive microorganisms for sustainable production, by exploiting their natural capability for producing metabolites. The potential of metabolically engineered cyanobacterium would depend on its source-sink balance in the same way as other phototrophs. In cyanobacteria, the amount of light energy harvested (Source) is incompletely utilized by the cell to fix carbon (sink) resulting in wastage of the absorbed energy causing photoinhibition and cellular damage leading to lowered photosynthetic efficiency. Although regulatory pathways like photo-acclimation and photoprotective processes can be helpful unfortunately they limit the cell's metabolic capacity. This review describes approaches for source-sink balance and engineering heterologous metabolic sinks in cyanobacteria for enhanced photosynthetic efficiency. The advances for engineering additional metabolic pathways in cyanobacteria are also described which will provide a better understanding of the cyanobacterial source-sink balance and approaches for efficient cyanobacterial strains for valuable metabolites.

Laboratory- and Pilot-Scale Cultivation of Tetraselmis striata to Produce Valuable Metabolic Compounds

Marine microalgae are considered an important feedstock of multiple valuable metabolic compounds of high biotechnological potential. In this work, the marine microalga Tetraselmis striata was cultivated in different scaled photobioreactors (PBRs). Initially, experiments were performed using two different growth substrates (a modified F/2 and the commercial fertilizer Nutri-Leaf (30% TN-10% P-10% K)) to identify the most efficient and low-cost growth medium. These experiments took place in 4 L glass aquariums at the laboratory scale and in a 9 L vertical tubular pilot column. Enhanced biomass productivities (up to 83.2 mg L^-1 d^-1) and improved biomass composition (up to 41.8% d.w. proteins, 18.7% d.w. carbohydrates, 25.7% d.w. lipids and 4.2% d.w. total chlorophylls) were found when the fertilizer was used. Pilot-scale experiments were then performed using Nutri-Leaf as a growth medium in different PBRs: (a) a paddle wheel, open, raceway pond of 40 L, and (b) a disposable polyethylene (plastic) bag of 280 L working volume. Biomass growth and composition were also monitored at the pilot scale, showing that high-quality biomass can be produced, with important lipids (up to 27.6% d.w.), protein (up to 45.3% d.w.), carbohydrate (up to 15.5% d.w.) and pigment contents (up to 4.2% d.w. total chlorophylls), and high percentages of eicosapentaenoic acid (EPA). The research revealed that the strain successfully escalated in larger volumes and the biochemical composition of its biomass presents high commercial interest and could potentially be used as a feed ingredient.

Optimizing phosphorus removal for municipal wastewater post-treatment with Chlorella vulgaris

The microalgal species Chlorella vulgaris was cultivated in batch conditions to identify the optimum set of initial conditions for the best biomass growth rate, phosphate removal, polyphosphate accumulation, and protein productivity. To study the effect of phosphorus deficiency caused stress, the microalgal biomass was exposed to phosphorus deficiency conditions for periods varying between 1 and 10 days and inoculated at different initial biomass and phosphate concentrations. A 10-day period of phosphate deficiency, supported by low initial biomass concentration (∼0.25 mg DW L^-1), increased the phosphate removal by 62-175% when compared to the reference conditions. A 10-day period of biomass P-deficiency also boosted the polyphosphate accumulation and protein productivity, increasing them up to 40 and 46.8 times, respectively, if compared to reference conditions. At the same time, optimization algorithm model results suggested one-day biomass P-starvation with low initial biomass concentration as the optimum combination to achieve the highest performance while the initial phosphate concentration had less impact. The initial conditions suggested by the optimization model were validated in a sequencing batch photobioreactor, giving 101.7 and 138.0% more phosphate removal and polyphosphate accumulation, compared to the reference conditions. The obtained results present microalgae exposure to phosphorus stress as a supplementary tool for wastewater post-treatment targeted on rapid phosphorus removal.

Microalgal remediation and valorisation of polluted wastewaters for zero-carbon circular bioeconomy

Overexploitation of natural resources to meet human needs has considerably impacted CO₂ emissions, contributing to global warming and severe climatic change. This review furnishes an understanding of the sources, brutality, and effects of CO₂ emissions and compelling requirements for metamorphosis from a linear to a circular bioeconomy. A detailed emphasis on microalgae, its types, properties, and cultivation are explained with significance in attaining a zero-carbon circular bioeconomy. Microalgal treatment of a variety of wastewaters with the conversion of generated biomass into value-added products such as bio-energy and pharmaceuticals, along with agricultural products is elaborated. Challenges encountered in large-scale implementation of microalgal technologies for low-carbon circular bioeconomy are discussed along with solutions and future perceptions. Emphasis on the suitability of microalgae in wastewater treatment and its conversion into alternate low-carbon footprint bio-energies and value-added products enforcing a zero-carbon circular bioeconomy is the major focus of this review.

Optimization of CO2 Supply for the Intensive Cultivation of Chlorella sorokiniana IPPAS C-1 in the Laboratory and Pilot-Scale Flat-Panel Photobioreactors

Microalgae are increasingly being used for capturing carbon dioxide and converting it into valuable metabolites and biologically active compounds on an industrial scale. The efficient production of microalgae biomass requires the optimization of resources, including CO₂. Here, we estimated the productivity of Chlorella sorokiniana IPPAS C-1 depending on CO₂ concentrations and the ventilation coefficient of the gas-air mixture (GAM) in flat-panel photobioreactors (FP-PBRs) at laboratory (5 L) and pilot (18 L) scales. For the laboratory scale, the PBRs operated at 900 µmol quanta m⁻² s⁻¹ and 35.5 ± 0.5 °C; the optimal CO₂ flow rate was estimated at 3 mL CO₂ per 1 L of suspension per minute, which corresponds to 1.5% CO₂ in the GAM and an aeration rate of 0.2 vvm. These parameters, being scaled up within the pilot PBRs, resulted in a high specific growth rate (µ ≈ 0.1 h⁻¹) and high specific productivity (P_sp ≈ 1 g dw L⁻¹ d⁻¹). The principles of increasing the efficiency of the intensive cultivation of C. sorokiniana IPPAS C-1 are discussed. These principles are relevant for the development of technological regimes for the industrial production of Chlorella in flat-panel PBRs of various sizes.

Optimization of Microalgal Harvesting with Inorganic and Organic Flocculants Using Factorial Design of Experiments

Microalgae have a lot of potential as a source of several compounds of interest to various industries. However, developing a sustainable and efficient harvesting process on a large scale is still a major challenge. This is particularly a problem when the production of low-value products is intended. Chemical flocculation, followed by sedimentation, is seen as an alternative method to improve the energetic and economic balance of the harvesting step. In this study, inorganic (aluminum sulfate, ferric sulfate, ferric chloride) and organic (Zetag 8185, chitosan, Tanfloc SG) flocculants were tested to harvest Chlorella vulgaris in batch mode. Preliminary assays were conducted to determine the minimum dosages of each flocculant that generates primary flocs at different pH. Except for chitosan, the organic flocculants required small dosages to initiate floc formation. Additional studies were performed for the flocculants with a better performance in the preliminary assays. Zetag 8185 had the best results, reaching 98.8% and 97.9% efficiencies with dosages of 50 and 100 mg L−1, respectively. Lastly, a 24 full factorial design experiment was performed to determine the effects of the flocculant dosage, settling time, and mixing time on the Zetag 8185 harvesting efficiency. The harvesting efficiency of C. vulgaris was optimal at a dosage of 100 mg L−1 and 3 min of rapid mixing.