New ultra-flat photobioreactor for intensive microalgal production: The effect of light irradiance

Perspectives on cultivation and harvesting technologies of microalgae, towards environmental sustainability and life cycle analysis

The development of algae is seen as a potential and ecologically sound approach to address the increasing demands in multiple sectors. However, successful implementation of processes is highly dependent on effective growing and harvesting methods. The present study provides a complete examination of contemporary techniques employed in the production and harvesting of algae, with a particular emphasis on their sustainability. The review begins by examining several culture strategies, encompassing open ponds, closed photobioreactors, and raceway ponds. The analysis of each method is conducted in a systematic manner, with a particular focus on highlighting their advantages, limitations, and potential for expansion. This approach ensures that the conversation is in line with the objectives of sustainability. Moreover, this study explores essential elements of algae harvesting, including the processes of cell separation, dewatering, and biomass extraction. Traditional methods such as centrifugation, filtration, and sedimentation are examined in conjunction with novel, environmentally concerned strategies including flocculation, electro-coagulation, and membrane filtration. It evaluates the impacts on the environment that are caused by the cultivation process, including the usage of water and land, the use of energy, the production of carbon dioxide, and the runoff of nutrients. Furthermore, this study presents a thorough examination of the current body of research pertaining to Life Cycle Analysis (LCA) studies, presenting a perspective that emphasizes sustainability in the context of algae harvesting systems. In conclusion, the analysis ends up with an examination ahead at potential areas for future study in the cultivation and harvesting of algae. This review is an essential guide for scientists, policymakers, and industry experts associated with the advancement and implementation of algae-based technologies.

Design parameters comparison of bubble column, airlift and stirred tank photobioreactors for microalgae production

Microalgae are the most propitious feedstock for biofuel production due to their lipid and fatty acid content. Microalgae cultivation shares many features with bioreactors, such as thermal and pH regulation, feeding procedures, and mixing to enhance heat and mass transfers. Aeration and stirring speeds are important parameters to reduce the costs of producing microalgae. In this study, three different photobioreactor types (stirred tank, airlift, bubble column) were characterized and compared for microalgae production. Hydrodynamics, mass transfer, and power consumption were determined for various aeration rates (0.9, 1.2, 1.5 L/min), and stirring speeds (100, 200 rpm), and Chlorella sorokiniana growth performance was compared under the conditions that provided the highest volumetric mass transfer and the lowest mixing time. Photo-bioreactor homogenization was good as indicated by low mixing times (< 10 s). Bubble column had the highest volumetric mass transfer due to its sparger design. Gas holdup and volumetric mass transfer coefficient were found to increase with the air flow rate and stirring speed. For stirred tank, bubble column, and airlift photobioreactors, maximum specific growth rates of C. sorokiniana were 0.053, 0.061, 0.057 h-1, and biomass productivities were 0.064, 0.097, 0.072 gdw/L.day, respectively. Under the conditions tested, growth was limited by the volumetric mass transfer in the airlift and stirred tank and bubble column was the best option for producing microalgae. These findings pave way for more extensive use of these systems in producing microalgae and provide a basis to compare photobioreactors of different designs.

Impact of 3D printing materials on mircoalga Chlorella vulgaris

3D printing represents a key enabling technology in designing photobioreactors. It allows rapid prototyping of complex geometries at an affordable price. Yet, no study dealt with the biocompatibility of 3D printing material with microalgae. Thus microalga Chlorella vulgaris was cultivated in contact with different 3D printing materials (Acrylonitrile Butadiene Styren - ABS, PolyCarbonate Blend - PC-Blend, PolyLactic acid - PLA, and acrylate methacrylate resin). Cell status was analyzed using flow cytometry, fluorometry, and pigment profiling. Results revealed that acrylate methacrylate resin material inhibits growth, a constant rise in intracellular reactive oxygen species, and a decrease in photosynthetic apparatus functioning. On the contrary, ABS, PC-Blend, and PLA led to nominal perfromances. Nevertheless, PLA was the only material that did not induce an early onset of intracellular reactive oxygen species. Therefore, resin can be ruled out as photobioreactor material, ABS and PC-Blend could be used after a curation period, and PLA induces no detectable perturbations by the means used in this study.

Biotechnologies for bulk production of microalgal biomass: from mass cultivation to dried biomass acquisition

Microalgal biomass represents a sustainable bioresource for various applications, such as food, nutraceuticals, pharmaceuticals, feed, and other bio-based products. For decades, its mass production has attracted widespread attention and interest. The process of microalgal biomass production involves several techniques, mainly cultivation, harvesting, drying, and pollution control. These techniques are often designed and optimized to meet optimal growth conditions for microalgae and to produce high-quality biomass at acceptable cost. Importantly, mass production techniques are important for producing a commercial product in sufficient amounts. However, it should not be overlooked that microalgal biotechnology still faces challenges, in particular the high cost of production, the lack of knowledge about biological contaminants and the challenge of loss of active ingredients during biomass production. These issues involve the research and development of low-cost, standardized, industrial-scale production equipment and the optimization of production processes, as well as the urgent need to increase the research on biological contaminants and microalgal active ingredients. This review systematically examines the global development of microalgal biotechnology for biomass production, with emphasis on the techniques of cultivation, harvesting, drying and control of biological contaminants, and discusses the challenges and strategies to further improve quality and reduce costs. Moreover, the current status of biomass production of some biotechnologically important species has been summarized, and the importance of improving microalgae-related standards for their commercial applications is noted.

Progress on microalgae cultivation in wastewater for bioremediation and circular bioeconomy

Water usage increased alongside its competitiveness due to its finite amount. Yet, many industries still rely on this finite resource thus recalling the need to recirculate their water for production. Circular bioeconomy is presently the new approach emphasizing on the 'end-of-life' concept with reusing, recycling, and recovering materials. Microalgae are the ideal source contributing to circular bioeconomy as it exhibits fast growth and adaptability supported by biological rigidity which in turn consumes nutrients, making it an ideal and capable bioremediating agent, therefore allowing water re-use as well as its biomass potential in biorefineries. Nevertheless, there are challenges that still need to be addressed with consideration of recent advances in cultivating microalgae in wastewater. This review aimed to investigate the potential of microalgae biomass cultivated in wastewater. More importantly, how it'll play a role in the circular bioeconomy. This includes an in-depth look at the production of goods coming from wastes tattered by emerging pollutants. These emerging pollutants include microplastics, antibiotics, ever-increasingly sewage water, and heavy metals which have not been comprehensively compared and explored. Therefore, this review is aiming to bring new insights to researchers and industrial stakeholders with interest in green alternatives to eventually contribute towards environmental sustainability.

Modeling and Simulation of Photobioreactors with Computational Fluid Dynamics—A Comprehensive Review

Computational Fluid Dynamics (CFD) have been frequently applied to model the growth conditions in photobioreactors, which are affected in a complex way by multiple, interacting physical processes. We review common photobioreactor types and discuss the processes occurring therein as well as how these processes have been considered in previous CFD models. The analysis reveals that CFD models of photobioreactors do often not consider state-of-the-art modeling approaches. As a comprehensive photobioreactor model consists of several sub-models, we review the most relevant models for the simulation of fluid flows, light propagation, heat and mass transfer and growth kinetics as well as state-of-the-art models for turbulence and interphase forces, revealing their strength and deficiencies. In addition, we review the population balance equation, breakage and coalescence models and discretization methods since the predicted bubble size distribution critically depends on them. This comprehensive overview of the available models provides a unique toolbox for generating CFD models of photobioreactors. Directions future research should take are also discussed, mainly consisting of an extensive experimental validation of the single models for specific photobioreactor geometries, as well as more complete and sophisticated integrated models by virtue of the constant increase of the computational capacity.

Cyanobacterial biorefinery: Towards economic feasibility through the maximum valorization of biomass

Cyanobacteria are well known for their plethora of applications in the fields of food industry, pharmaceuticals and bioenergy. Their simple growth requirements, remarkable growth rate and the ability to produce a wide range of bio-active compounds enable them to act as an efficient biorefinery for the production of valuable metabolites. Most of the cyanobacteria based biorefineries are targeting single products and thus fails to meet the efficient valorization of biomass. On the other hand, multiple products recovering cyanobacterial biorefineries can efficiently valorize the biomass with minimum to zero waste generation. But there are plenty of bottlenecks and challenges allied with cyanobacterial biorefineries. Most of them are being associated with the production processes and downstream strategies, which are difficult to manage economically. There is a need to propose new solutions to eliminate these tailbacks so on to elevate the cyanobacterial biorefinery to be an economically feasible, minimum waste generating multiproduct biorefinery. Cost-effective approaches implemented from production to downstream processing without affecting the quality of products will be beneficial for attaining economic viability. The integrated approaches in cultivation systems as well as downstream processing, by simplifying individual processes to unit operation systems can obviously increase the economic feasibility to a certain extent. Low cost approaches for biomass production, multiparameter optimization and successive sequential retrieval of multiple value-added products according to their high to low market value from a biorefinery is possible. The nanotechnological approaches in cyanobacterial biorefineries make it one step closer to the goal. The current review gives an overview of strategies used for constructing self-sustainable- economically feasible- minimum waste generating; multiple products based cyanobacterial biorefineries by the efficient valorization of biomass. Also the possibility of uplifting new cyanobacterial strains for biorefineries is discussed.

Microalgae-based carbohydrates: A green innovative source of bioenergy

Microalgae contribute significantly to the global carbon cycle through photosynthesis. Given their ability to efficiently convert solar energy and atmospheric carbon dioxide into chemical compounds, such as carbohydrates, and generate oxygen during the process, microalgae represent an excellent and feasible carbohydrate bioresource. Microalgae-based biofuels are technically viable and, delineate a green and innovative field of opportunity for bioenergy exploitation. Microalgal polysaccharides are one of the most versatile groups for biotechnological applications and its content can be increased by manipulating cultivation conditions. Microalgal carbohydrates can be used to produce a variety of biofuels, including bioethanol, biobutanol, biomethane, and biohydrogen. This review provides an overview of microalgal carbohydrates, focusing on their use as feedstock for biofuel production, highlighting the carbohydrate metabolism and approaches for their enhancement. Moreover, biofuels produced from microalgal carbohydrate are showed, in addition to a new bibliometric study of current literature on microalgal carbohydrates and their use.

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.

Starch Production in Chlamydomonas reinhardtii through Supraoptimal Temperature in a Pilot-Scale Photobioreactor

An increase in temperature can have a profound effect on the cell cycle and cell division in green algae, whereas growth and the synthesis of energy storage compounds are less influenced. In Chlamydomonas reinhardtii, laboratory experiments have shown that exposure to a supraoptimal temperature (39 °C) causes a complete block of nuclear and cellular division accompanied by an increased accumulation of starch. In this work we explore the potential of supraoptimal temperature as a method to promote starch production in C. reinhardtii in a pilot-scale photobioreactor. The method was successfully applied and resulted in an almost 3-fold increase in the starch content of C. reinhardtii dry matter. Moreover, a maximum starch content at the supraoptimal temperature was reached within 1-2 days, compared with 5 days for the control culture at the optimal temperature (30 °C). Therefore, supraoptimal temperature treatment promotes rapid starch accumulation and suggests a viable alternative to other starch-inducing methods, such as nutrient depletion. Nevertheless, technical challenges, such as bioreactor design and light availability within the culture, still need to be dealt with.

Comparison of Galdieria growth and photosynthetic activity in different culture systems

In the last years, the acidothermophilic red microalga Galdieria sulphuraria has been increasingly studied for industrial applications such as wastewater treatment, recovery of rare earth elements, production of phycobilins. However, even now it is not possible an industrial cultivation of this organism because biotechnological research on G. sulphuraria and allied species is relatively recent and fragmented. Having in mind a possible scale-up for commercial applications, we have compared the growth and photosynthetic performance of G. sulphuraria in four suspended systems (Inclined bubble column, Decanter Laboratory Flask, Tubular Bioreactor, Ultra-flat plate bioreactor) and one immobilized system (Twin Layer Sytem). The results showed that G. sulphuraria had the highest growth, productivity and photosynthetic performance, when grown on the immobilized system, which also offers some economics advantages.

The Microalgae Biorefinery: A Perspective on the Current Status and Future Opportunities Using Genetic Modification

There is clear scientific evidence that emissions of greenhouse gases (GHG), arising from fossil fuel combustion and land-use change as a result of human activities, are perturbing the Earth’s climate. Microalgae-derived biofuels have been chased since the 1980s without success but, lately, a new biorefinery concept is receiving increasing attention. Here, we discuss the possible solutions to the many problems that make this process unrealised to date, considering also the possibility of including genetically modified (GM) organisms to improve the productivity and process economics. Currently, unless coupled to a service or higher value product production, biofuels derived from microalgae fail to achieve economic reality. However, provided sufficient development of new technologies, potentially including new or improved organisms to lower both production and processing costs, as well as looking at the utility of distributed versus centralised production models, algae biofuels could achieve an impact, off-setting our heavy reliance on petroleum-based liquid fuels.