Open thin-layer cascade reactors for saline microalgae production evaluated in a physically simulated Mediterranean summer climate

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.

Effects of fluid-flow regimes on Chlorella sorokiniana cultivation in cascade photobioreactors with either flat or wavy bottoms

Computational fluid dynamics (CFD) was used to investigate cascade photobioreactors (cascade PBRs) with two different bottom configurations-flat and wavy-to establish the effect that fluid-flow regimes exert on the photosynthetic productivity of Chlorella sorokiniana. In the flat-bottom PBR, areal biomass productivities decreased from 6.8 to 4.2 g·m^-2·d^-1 when the flow rate of a culture per unit of lane width was increased from 33 to 132 L·m^-1·min^-1. We found that this decrease in the areal productivity was the result of a decrease in the volumetric photon flux densities (volumetric PFDs), which was caused by an increase in the depth of the culture in the lane. Through CFD calculation and long-exposure photography, the flow of the culture in the wavy-bottom PBR was characterized in an upper straightforward section and underneath the swirling section. Under identical conditions of flow rate and volumetric PFD (66 L·m^-1·min^-1 and 50 μmol·m^-3·s^-1, respectively), the cell growth accelerated in the wavy-bottom PBR with areal productivity that reached 6.5 g·m^-2·d^-1-productivity was 5.1 g·m^-2·d^-1 in the flat-bottom PBR. The swirling flow in the wave troughs held the culture for longer periods in the illuminated lane, and the resultant extended period of mixing improved the photosynthetic productivity.

Renewable Fuels from Integrated Power- and Biomass-to-X Processes: A Superstructure Optimization Study

This work presents a superstructure optimization study for the production of renewable fuels with a focus on jet fuel. Power-to-X via the methanol (MTJ) and Fischer–Tropsch (FT) route is combined with Biomass-to-X (BtX) via an algae-based biorefinery to an integrated Power- and Biomass-to-X (PBtX) process. Possible integration by algae remnant utilization for H2/CO2 production, wastewater recycling and heat integration is included. Modeling is performed using the novel Open sUperstrucTure moDeling and OptimizatiOn fRamework (OUTDOOR). Novel methods to account for advanced mass balances and uncertain input data are included. Economic optimization proposes a PBtX process. This process combines algae processing with MTJ and depicts a highly mass- and energy integrated plant. It produces fuels at 211 EUR/MWhLHV (ca. 2530 EUR/t), a cost reduction of 21% to 11.5% compared to stand-alone electricity- or bio-based production at algae costs of 25 EUR/tAlgae-sludge and electricity costs of 72 EUR/MWh. Investigation of uncertain data indicates that a combination of BtX and MTJ is economically superior to FT for a wide parameter range. Only for high algae costs of >40 EUR/tAlgae-sludge stand-alone electricity-based MTJ is economically superior and for high MTJ costs above 2000–2400 EUR/tJet FT is the optimal option.

Naturally illuminated photobioreactors for resource recovery from piggery and chicken-processing wastewaters utilising purple phototrophic bacteria

Resource recovery from wastewater, preferably as high value products, has become an integral part of modern wastewater treatment. This work presents the potential to produce single cell protein (SCP) from pre-settled piggery wastewater (PWW) and meat chicken processing wastewater (CWW), utilising anaerobic purple phototrophic bacteria (PPB). PPB were grown as biofilm in outdoors 60 L, 80 L and 100 L flat-plate reactors, operated in sequential batch mode. PPB biofilm was recovered from reactor walls at a total solid (TS) content ∼90 g•L - 1, and the harvested biomass (depending on the wastewater) had a consistent quality, with high protein contents (50-65%) and low ash, potentially applicable as SCP. The COD, N and P removal efficiencies were 71±5.3%, 22±6.6%, 65±5.6% for PWW and 78±1.8%, 67±2.7% and 37±4.0% for CWW, respectively, with biofilm areal productivities up to 14 g TS•m - 2•d - 1. This was achieved at ammonium-N concentrations over 1.0 g•L - 1 and temperatures up to 55 °C and down to 6 °C (daily fluctuations of 20-30 °C). The removal performances and biomass productivities were mostly dependent on the bioavailable COD in the form of volatile fatty acids (VFA). At sufficient VFA availability, the irradiance became limiting, capping biofilm formation. Harvesting of the suspended fraction resulted in increased productivities and recovery efficiencies, but lowered the product quality (e.g., containing undesired inerts). The optimum between quantity and quality of product is dependent on the wastewater characteristics (i.e., organic degradable fraction) and potential pre-treatment. This study shows the potential to utilise sunlight to treat agri-industrial wastewaters while generating protein-rich PPB biomass to be used as a feed, feed additive or feed supplement.

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.

Annual assessment of the wastewater treatment capacity of the microalga Scenedesmus almeriensis and optimisation of operational conditions

The depth of the culture and the dilution rate have a striking effect on the biomass productivity and the nutrient recovery capacity of microalgal cultures. The combination of culture depth and dilution rate that allows to maximise the performance of the system depends on environmental conditions. In the current study, a response surface methodology was used to explore the relationship between the two most relevant operational conditions and the biomass productivity achieved in 8.3 m² pilot-scale raceways operated using urban wastewater. Four polynomial models were developed, one for each season of the year. The software predicted biomass productivities of 12.3, 25.6, 32.7, and 18.9 g·m^-2·day^-1 in winter, spring, summer, and autumn, respectively. The models were further validated at pilot-scale with R² values ranging within 0.81 and 0.91, depending on the season. Lower culture depths had the advantage of minimising nitrification and stripping but allow to process a lower volume of wastewater per surface area. Biomass productivity was higher at culture depths of 0.05 m, when compared to 0.12 and 0.20 m, while the optimal dilution rate was season-dependent. Results reported herein are useful for optimising the biomass productivity of raceway reactors located outdoors throughout the year.

Internal Illumination to Overcome the Cell Density Limitation in the Scale-up of Whole-Cell Photobiocatalysis

Cyanobacteria have the capacity to use photosynthesis to fuel their metabolism, which makes them highly promising production systems for the sustainable production of chemicals. Yet, their dependency on visible light limits the cell-density, which is a challenge for the scale-up. Here, it was shown with the example of a light-dependent biotransformation that internal illumination in a bubble column reactor equipped with wireless light emitters (WLEs) could overcome this limitation. Cells of the cyanobacterium Synechocystis sp. PCC 6803 expressing the gene of the ene-reductase YqjM were used for the reduction of 2-methylmaleimide to (R)-2-methylsuccinimide with high optical purity (>99 % ee). Compared to external source of light, illumination by floating wireless light emitters allowed a more than two-fold rate increase. Under optimized conditions, product formation rates up to 3.7 mm h-1 and specific activities of up to 65.5 U gDCW -1 were obtained, allowing the reduction of 40 mm 2-methylmaleimide with 650 mg isolated enantiopure product (73 % yield). The results demonstrate the principle of internal illumination as a means to overcome the intrinsic cell density limitation of cyanobacterial biotransformations, obtaining high reaction rates in a scalable photobioreactor.

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.

Life cycle greenhouse gas emissions of microalgal fuel from thin-layer cascades

Thin-layer cascades (TLCs) enable algae cultivation at high cell densities, thus increasing biomass yields and facilitating the harvest process. This makes them a promising technology for industrial-scale algal fuel production. Using Life Cycle Assessment (LCA), we calculate the greenhouse gas (GHG) emissions of aviation fuel produced using algal biomass from TLCs. We find that the impact (81 g CO₂e per MJ) is lower than that of fuel from algal biomass cultivated in open race way ponds (94 g CO₂e). However, neither of the two cultivation systems achieve sufficient GHG savings for compliance with the Renewable Energy Directive II. Seawater desalination in particular dominates the TLC impact, indicating a trade-off between carbon and water footprint. In both cultivation systems, the mixing power and fertilizer consumption present further significant impacts. There is uncertainty in the correlation between mixing power and algal oil yield, which should be investigated by future experimental studies.

Climate-Simulated culturing suggests high microalgal biomass and oil productivities in most of the South American continent

BACKGROUND

Current production costs of microalgal biomass indicate that only highly-productive cultivation facilities will approach commercial feasibility. Geographical site selection for siting those facilities is critical for achieving target productivities. The aim of this study was to provide a semi-empirical estimation of microalgal biomass and lipids productivity in South America.

METHODS AND RESULTS

Simulated-climate was programed in environmental photobioreactors (Phenometrics) for a simulation of cultivation in open raceway ponds at different geographical sites. The mean annual South American biomass productivity of 20-cm deep ponds was 12 ± 4 g · m^{- 2} · d^-1 . The most productive regions were clustered in the subtropical and tropical regions of the continent. Fortaleza (Brazil) showed a low seasonality and a high annual mean productivity of 23 g · m^-2 · d^-1 in 5-cm deep ponds, closely approaching the productivity target. Lipids accumulation and productivity in Fortaleza showed a high microalgal oil accumulation up to 46% (w/w) and a maximum oil productivity of 5 g · m^-2 · d^-1 for biomass containing around 20% lipids (w/w).

CONCLUSION

This study provides the first semi-empirical estimation of microalgal productivity in South America and supports a high potential of a vast region of the continent.

Application of attached algae flow-ways for coupling biomass production with the utilization of dilute non-point source nutrients in the Upper Laguna Madre, TX

The purpose of this study is to determine the potential for an attached algae flow-way system to efficiently produce algal biomass in estuarine surface waters by utilizing dilute non-point source nutrients from local urban, industrial, and agricultural discharges into the Upper Laguna Madre, Corpus Christi, Texas. The study was conducted over the course of two years to establish seasonal base-line biomass productivity and composition for bioproducts applications, and to identify key environmental factors and flow-way cohorts impacting biomass production. For the entire cultivation period, continuous ash-free biomass production at 4 to 10 g/m²/day (corresponding to nutrient recovery at 300 to 500 mg of nitrogen/m²/day and 15 to 30 mg of phosphorus/m²/day) was successfully achieved without system restart. Upon start-up, a latency period was observed which indicates roles for species succession from relatively low productivity, high ash content pioneer periphytic culture composed primarily of benthic diatoms from the source waters to higher productivity, reduced ash content, and more resilient culture mainly composed of filamentous chlorophyta, Ulva lactuca. Principal Component Analysis (PCA) was used to identify environmental factors driving biomass production, and machine learning (ML) models were constructed to assess the predictive capability of the data set for system performance using the local multi-season environmental variations. Environmental datasets were segregated for ML training, validation, and testing using three methods: regression tree, ensemble regression, and Gaussian process regression (GPR). The predicted ash-free biomass productivity using ML models resulted in root-squared-mean-errors (RSME) from 1.78 to 1.86 g/m²/day, and R² values from 0.67 to 0.75 using different methods. The greatest contributor to net productivity was total solar irradiation, followed by air temperature, salinity, and pH. The results of the study should be useful as a decision-making tool to application of attached algae flow-ways for biomass production while preventing algal blooms in the environment.

Production of β-carotene with Dunaliella salina CCAP19/18 at physically simulated outdoor conditions

Batch growth and β-carotene production of Dunaliella salina CCAP19/18 was investigated in flat-plate gas-lift photobioreactors with a light path of 2 cm, operated in physically simulated outdoor conditions. Dunaliella salina CCAP19/18 showed robust growth with respect to pH 8.0-9.0 and 15-35°C at increasing salinity, simulating the evaporation of open photobioreactors. The highest β-carotene concentration of 25 mg L-1 (3 mg gCDW -1) was observed in batch processes at pH 8.5, 15-30°C and increasing salinity up to 110 g L-1, simulating a typical Mediterranean summer climate. Intracellular β-carotene accumulation of D. salina CCAP19/18 was shown to be independent of light availability, although nutrient limitation (K2HPO4, MgSO4, and/or ammonium ferric citrate) seems to enable stable β-carotene content in the algal cells despite increasing cell densities in the photobioreactor. Fully controlled, lab-scale photobioreactors simulating typical climate conditions of any region of interest are valuable tools for enabling a realistic characterization of microalgae on a laboratory scale, for production processes projected in open photobioreactor systems (e.g. thin-layer cascade photobioreactors).

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.

Application of purple phototrophic bacteria in a biofilm photobioreactor for single cell protein production: Biofilm vs suspended growth

Single cell protein (SCP), has been proposed as alternative to effectively upgrade and recycle organics and nutrients from wastewater. Biomass recovery is a critical issue, and recovery as a biofilm is effective in comparison with sedimentation of suspended biomass. This study aims to determine the applicability of purple phototrophic bacteria (PPB) biofilm on infra-red irradiated, submerged surfaces for the treatment of pre-settled red meat processing wastewater, and SCP generation. PPB removed up to 66% of COD and 42% of TN and TP during batch operation with total areal productivities between 15 and 20 gVS m^-2 d^-1 achieved. More than 60% of the total biomass grew attached (as biofilm) with the remainder being suspended. The biofilm can be harvested at around 160 gTS L^-1 with high protein (>96 g L^-1) and low ash contents (>4.0% compared to >30% in the wastewater). The compositions of attached and suspended biomass differed significantly, where the suspended fraction resembled the wastewater composition (e.g. in terms of inert components). The PPB community was similar in the suspended and biofilm fractions while the biofilm had higher relative abundance of PPB representatives (57% vs 43%). A consistent product composition is highly relevant for the manufacturer and ultimately determines the value as feed, feed additive, or supplement.

High-Density Microalgae Cultivation in Open Thin-Layer Cascade Photobioreactors with Water Recycling

(1) Background: Recycling of water and non-converted nutrients is considered to be a necessity for an economically viable production of microalgal biomass as a renewable feedstock. However, medium recycling might also have a negative impact on algal growth and productivity due to the accumulation of growth-inhibiting substances. (2) Methods: Consecutive batch processes with repeated water recycling after harvesting of algal biomass were performed with the saline microalga Microchloropsis salina in open thin-layer cascade photobioreactors operated at a physically simulated Mediterranean summer climate. The impact of water recycling on culture performance was studied and the composition of the recycled water was analyzed. (3) Results: Water recycling had no adverse effect on microalgal growth and biomass productivity (14.9−21.3 g m−2 d−1) if all necessary nutrients were regularly replenished and KNO3 was replaced by urea as the nitrogen source to prevent the accumulation of K+ ions. Dissolved organic carbon accumulated in recycled water, probably promoting mixotrophic growth. (4) Conclusion: This study shows that repeated recycling of water is feasible even in high-density cultivation processes with M. salina of more than 30 g L−1 cell dry weight, increasing culture performance while reducing nutrient consumption and circumventing wastewater production.

Production of lipids with Microchloropsis salina in open thin-layer cascade photobioreactors

Microalgal biomass is considered as the most promising feedstock for sustainable production of liquid fuels. Lipid production with Microchloropsis salina was studied in open thin-layer cascade (TLC) photobioreactors with a surface area of 8 m² applying a physically simulated Mediterranean summer climate. High lipid concentrations of up to 6.6 g L^-1 with 46% (w w^-1) total lipids in dry cell mass were achieved in two-phase batch processes applying a nitrogen limitation. The two-phase batch process was transferred into a continuously operated reactor cascade of two TLC photobioreactors. Microchloropsis salina cells were produced continuously in the first photobioreactor, whereas continuous lipid production was enabled in the second, nitrogen-limited TLC photobioreactor resulting in continuous production of 3.0 g L^-1 lipids with a high overall lipid space-time-yield of 0.2 g L^-1 d^-1. The control of alkalinity to about 10 mM resulted in high CO₂ conversion efficiencies of 84-87%.

Validated numerical fluid simulation of a thin-layer cascade photobioreactor in OpenFOAM

Recently, microalgae have been considered as a promising alternative for the production of biofuels from CO₂. For the efficient cultivation of these microalgae, several types of photobioreactors have been designed and Pilot scale photobioreactors have been used to assess the performance of these reactors. Therein the primarily investigated reactor type is the Raceway Pond. However, the less researched Thin-Layer Cascade Photobioreactor (TLC) shows a high potential for efficient production processes. Unfortunately, for low-value products like biofuels costs must be kept to a minimum for an economic operation. To facilitate this, 3D Computational Fluid Dynamic simulations can be employed to estimate performance of reactor variants e.g. with respect to power input and mixing. Since up to now little effort has been put into the modelling of TLC reactors, this report aims to present a simulation approach for these reactors types that allows simple adaptation to different geometric or operational boundary conditions. All models have been generated for a two-phase mixture in OpenFOAM. To demonstrate its applicability, validation measurements with a physical unit have been performed and were compared to the simulation results. With errors in the order of 10 % a successful simulation of the reactor geometry could be proven.

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.

Recent developments in synthetic biology and metabolic engineering in microalgae towards biofuel production

In the wake of the uprising global energy crisis, microalgae have emerged as an alternate feedstock for biofuel production. In addition, microalgae bear immense potential as bio-cell factories in terms of producing key chemicals, recombinant proteins, enzymes, lipid, hydrogen and alcohol. Abstraction of such high-value products (algal biorefinery approach) facilitates to make microalgae-based renewable energy an economically viable option. Synthetic biology is an emerging field that harmoniously blends science and engineering to help design and construct novel biological systems, with an aim to achieve rationally formulated objectives. However, resources and tools used for such nuclear manipulation, construction of synthetic gene network and genome-scale reconstruction of microalgae are limited. Herein, we present recent developments in the upcoming field of microalgae employed as a model system for synthetic biology applications and highlight the importance of genome-scale reconstruction models and kinetic models, to maximize the metabolic output by understanding the intricacies of algal growth. This review also examines the role played by microalgae as biorefineries, microalgal culture conditions and various operating parameters that need to be optimized to yield biofuel that can be economically competitive with fossil fuels.