Numerical and experimental study on the CO2 gas–liquid mass transfer in flat-plate airlift photobioreactor with different baffles

Photobioreactors for utility-scale applications: effect of gas-liquid mass transfer coefficient and other critical parameters

Cultivation of microalgae and controlling its growth and performance in closed photobioreactors (PBRs) are easier than open pond systems for wastewater treatment. The performance of PBRs is influenced by geometry, hydrodynamic behavior, and mass transfer. Horizontal and vertical configurations as common designs of PBR are reviewed based on their features, advantages, and disadvantages. However, vertically operated PBRs like bubble columns are preferably used for utility-scale applications of microalgae-based processes. Moreover, an appropriate reactor design reduces the inhibitory effect of dissolved oxygen concentration produced by microalgae and consequently increases the level of available CO₂ in the medium. Medium properties, superficial gas velocity, gas holdup, bubble sizes, shear stress, mixing time, sparger design, and the ratio of inner diameter to effective height are shown to influence the overall volumetric mass transfer coefficient (K_La) and PBR's performance. The vertical PBRs like bubble columns provide a high mass transfer, a short liquid circulation time, and a long frequency of light/dark cycle for utility application of microalgae. Different flow regimes are obtained in PBRs based on the gas flow rate, inner diameter, and medium properties. Hydraulic retention time as the main operational parameter is determined in a batch mode for continuous wastewater treatment.

Design and characterization of a new pressurized flat panel photobioreactor for microalgae cultivation and CO2 bio-fixation

Microalgae-based biorefinery processes are gaining particular importance as a biotechnological tool for direct carbon dioxide fixation and production of high-quality biomass and energy feedstock for different industrial markets. However, despite the many technological advances in photobioreactor designs and operations, microalgae cultivation is still limited due to the low yields achieved in open systems and to the high investment and operation costs of closed photobioreactors. In this work, a new alveolar flat panel photobioreactor was designed and characterized with the aim of achieving high microalgae productivities and CO₂ bio-fixation rates. Moreover, the energy efficiency of the employed pump-assisted hydraulic circuit was evaluated. The 1.3 cm thick alveolar flat-panels enhance the light utilization, whereas the hydraulic design of the photobioreactor aims to improve the global CO₂ gas-liquid mass transfer coefficient (k_LaCO₂). The mixing time, liquid flow velocity, and k_LaCO₂ as well as the uniformity matrix of the artificial lighting source were experimentally calculated. The performance of the system was tested by cultivating the green microalga Acutodesmus obliquus. A volumetric biomass concentration equal to 1.9 g L^-1 was achieved after 7 days under controlled indoor cultivation conditions with a CO₂ bio-fixation efficiency of 64% of total injected CO₂. The (gross) energy consumption related to substrate handling was estimated to be between 27 and 46 Wh m^-3, without any cost associated to CO₂ injection and O₂ degassing. The data suggest that this pilot-scale cultivation system may constitute a relevant technology in the development of microalgae-based industrial scenario for CO₂ mitigation and biomass production.

Recent advances in computational fluid dynamics (CFD) modelling of photobioreactors: Design and applications

The development of photobioreactor is important for sustainable production of renewable fuels, wastewater treatment and CO₂ fixation. For the design and scale-up of a photobioreactor, CFD can be used as an indispensable tool. The present study reviews the recent status of computational flow modelling of various types of photobioreactors, involving fluid dynamics, light transport, and algal growth kinetics. An integrated modelling approach of hydrodynamics, light intensity, mass transfer, and biokinetics in photobioreactor is discussed further. Also, this reviews intensified system to improve the mixing, and light intensity of photobioreactors. Finally, the prospects and challenges of CFD modelling in photobioreactors are discussed. Multi-scale modelling approach and development of low-cost efficient computational framework are the areas to be considered for modelling of photobioreactor in near future. In addition, it is necessary to use process intensification techniques for photobioreactors for improving their hydrodynamics, mixing and mass transfer performances, and algal growth productivity.

Development a novel hexagonal airlift flat plate photobioreactor for the improvement of microalgae growth that simultaneously enhance CO2 bio-fixation and wastewater treatment

A novel hexagonal airlift flat plate (HAFP) photobioreactor was designed to improve microalgae growth rate and compared with traditional flat plate (TFP) photobioreactor. The computational fluid dynamics (CFD) simulation was used to determine hydrodynamic parameters and optimal aeration rate in the photobioreactors. Additionally, the capability of the HAFP photobioreactor to enhance microalgae based CO₂ bio-fixation and wastewater treatment were investigated. The results of CFD simulation indicated that the HAFP photobioreactor could improve hydrodynamic parameters of turbulence kinetic energy (TKE), average fluid velocity, dead zone (DZ), and water shear stress (WSS) up to 78 %, 41 %, 44 % and 40 %, respectively, under optimal aeration rate of 0.6 vvm. The proposed HAFP photobioreactor showed a drastic improvement in microalgae growth (up to 61 %). The maximum CO₂ removal of 53.8 % and bio-fixation of 0.85 g L^-1 d^-1 were achieved in the HAFP photobioreactor which were approximately 70 % more than that in the TFP photobioreactor. The results suggested that the HAFP photobioreactor could accelerate nutrients removal and achieve remarkably higher efficiencies of 91 %, 99 %, 97 % and 93 % of ammonia (NH₃), nitrate (NO₃^-), phosphate (PO₄^3-) and chemical oxygen demand (COD) within seven days of cultivation.

Computational fluid dynamics of rectangular external loop airlift reactor

The novel design of a rectangular external loop airlift reactor is at present the most used large-scale reactor for microalgae culture. It has a unique future for a large surface to volume ratio for exposure of light radiation for photosynthesis reaction. The 3D simulations have been performed in rectangular EL-ALR. The Eulerian–Eulerian approach has been used with a dispersed gas phase for different turbulent models. The performance and applicability of different turbulent model’s i.e., K-epsilon standard, K-epsilon realizable, K-omega, and Reynolds stress model are used and compared with experimental results. All drag forces and non-drag forces (turbulent dispersion, virtual mass, and lift coefficient) are included in the model. The experimental values of overall gas hold-up and average liquid circulation velocity have been compared with simulation and literature results. It is seemed to give good agreements. For the different elevations in the downcomer section, liquid axial velocity, turbulent kinetic energy, and turbulent eddy dissipation experimental have been compared with different turbulent models. The K-epsilon Realizable model gives better prediction with experimental results.

Improving light distribution and light/dark cycle of 900 L tangential spiral-flow column photobioreactors to promote CO2 fixation with Arthrospira sp. cells

The light distribution and light/dark cycle were improved in 900 L tangential spiral-flow column photobioreactors (TSCP) to promote CO₂ fixation with Arthrospira sp. cells. Solar irradiation model was employed in CFD simulation to investigate light distribution and light/dark cycle in flow field composed of culture medium, CO2 bubbles and Arthrospira sp. cells under actual sunlight irradiation considering geolocation and time. An accurate way to divide light/dark zone based on saturate light intensity and light intensity field was adopted for the first time. When Arthrospira sp. cell concentration increased from 0.1 to 0.9 g/L, light/dark cycle frequency of cells firstly increased from 0.650 Hz to 0.868 Hz and then decreased to 0.117 Hz. Intracellular chlorophyll a content and carotenoids content of Arthrospira sp. cells in TSCP were 6% and 41% higher than those in conventional bubble column photobioreactor. This promoted cellular photosynthesis and stress resistance, which contributed to increase CO₂ fixation rate of Arthrospira sp. cells by 59%. When CO₂ aeration rate, CO₂ volume concentration, and circulating pump power were 0.210 L/min, 15%, and 30 W, chlorophyll a content, helix pitch, and CO₂ fixation rate of Arthrospira sp. cells all reached peak values of 8.769 mg/L, 78.26 μm and 0.358 g/L/d, respectively.

Influence of photobioreactor configuration on microalgal biomass production

Biodiesel production from microalgae depends on the biomass concentration and lipid content in microalgal cells. Photobioreactors (PBRs) facilitates cultivation of microalgae and renders better process control than open systems. However, reactor configuration and consequential hydrodynamics considerably influence biomass and lipid production from microalgae. Here, four different configurations of PBRs, viz. airlift and bubble column with orifice sparger and newly designed ring sparger, were investigated. Resulting volumetric mass transfer coefficient, mixing time, and shear stress were analyzed at different air flow rates to realize their influence on biomass and lipid production from Neochloris oleoabundans UTEX 1185. Bubble column reactor with ring sparger was observed to exhibit superior performance, which was subsequently simulated using a two-phase Eulerian model to comprehend the influence of air flow rates on mixing time. The developed computational model corroborates well with the experimental findings of optimum air flow rate for maximum biomass yield in bubble column configuration.

A novel jet-aerated tangential swirling-flow plate photobioreactor generates microbubbles that enhance mass transfer and improve microalgal growth

To reduce bubble diameter and enhance mass transfer, a novel jet-aerated tangential swirling-flow plate photobioreactor was developed that improves the growth rate of microalgae. In this system, the circulating microalgal solution enters a jet aerator that takes up 15% CO₂ by vacuum suction and then injects into a plate photobioreactor through four centrally symmetric nozzles. Each jetflow is tangent to a tangential circle, driving vertical vortex movement of the surrounding microalgal solution, which markedly reduced the bubble diameter and enhanced mass transfer. The mass transfer coefficient was enhanced by decreasing the nozzle number (n) and increasing the ratio of tangential circle diameter to plate photobioreactor equivalent diameter (d/D). The average bubble diameter decreased by 80.2% to 0.37 mm and the mass transfer coefficient increased 4.6 times to 48.9 h^-1 when n was 4 and d/D was 0.34. Finally, the optimized system increased the biomass dry weight of microalgae by 49.4%.

Application of computational fluid dynamics to raceways combining paddlewheel and CO2 spargers to enhance microalgae growth

The present study investigated the effect of light intensity and mixing on microalgae growth in a raceway by comparing the performance of a paddlewheel to a combination of paddlewheel and CO₂ spargers in a 20 L raceway. The increase of light intensity was known to be able to increase the microalgal growth rate. Increasing paddlewheel rotation speed from 13 to 30 rpm enhanced C. vulgaris growth by enhancing culture mixing. Simulation results using computational fluid dynamics (CFD) indicated that both the turnaround areas of the raceway and the area opposite the paddlewheel experienced very low flow velocities (dead zones) of less than 0.1 m/min, which could cause cell settling and slow down growth. The simulated CFD velocity distribution in the raceway was validated by actual velocity measurements. The installation of CO₂ spargers in the dead zones greatly increased flow velocity. The increase of paddlewheel rotation speed reduced the dead zones and hence increased algal biomass production. By complementing the raceway paddlewheel with spargers providing CO₂ at 30 mL/min, we achieved a dry cell weight of 5.2 ± 0.2 g/L, which was about 2.6 times that obtained without CO₂ sparging.

Computational fluid dynamics simulation in scaling-up of airlift photobioreactor for astaxanthin production

The unicellular green microalga Haematococcus pluvialis accumulates large amounts of the red ketocarotenoid astaxanthin. Aiming to cultivate these microalgae with high astaxanthin efficiency, cultivations were scaled-up from 1000 mL bottle to 2 L and 8 L airlift photobioreactor using volumetric power consumption rate (W/m³) as scale up strategy. After cultivations, computational fluid dynamics (CFD) simulation was used to investigate the flow patterns, mixing efficiency and gas holdup profile within the 2 L photobioreactor. At the end, astaxanthin content was enhanced with increasing the cultivation volume and highest astaxanthin amount of 49.39 ± 1.64 mg/g cell was obtained in 8 L photobioreactor. Hydrodynamic characteristics of photobioreactor was simulated and gas holdup showed difference between the riser and the downcomer regions. Velocity profiles of air and medium had higher values inside the draft tube than obtained in downcomer region. However liquid circulation was achieved from draft tube to the downcomer, mixing was not provided effectively considering the turbulence kinetic energy. For the further research, some developments about column configuration, sparger diameter may be necessary to enhance the mixing characteristics.

Computational fluid dynamics modeling of carbon dioxide capture from air using biocatalyst in an airlift reactor

In this work, a novel three-phase and three dimensional CFD model based on the Euler-Euler approach developed for modeling the hydrodynamic, mass transfer and CO₂ fixation using microalgae in an internal loop airlift reactor with internal sparger. The main objective of this work was to development of CFD codes in order to simulate the CO₂ biofixation process under different input gas velocity during 11 days of culture time and simulate the unsteady state mass transfer based on Surface-Renewal-Stretch (SRS) model. The CFD results were compared with the our previous experimental work and they showed good agreement with a margin of less than 10%. This paper illustrated the ability of the CFD in complex process simulation such as CO₂ biofixation in the airlift reactor and provided a useful basis for further study.

Improving microalgal growth by strengthening the flashing light effect simulated with computational fluid dynamics in a panel bioreactor with horizontal baffles

Biological CO₂ elimination by photosynthetic microalgae is a sustainable way to mitigate CO₂ from flue gas and other sources. Computational fluid dynamics was used to simulate algal cell movement with an enhanced flashing light effect in a novel panel bioreactor with horizontal baffles. Calculation results showed that the light/dark (L/D) cycle period decreased by 17.5% from 17.1 s to 14.1 s and that the horizontal fluid velocity increased by 95% while horizontal baffles were used under a 0.02 vvm air aeration rate and a microalgal concentration of 0.85 g L⁻¹. The probability of the L/D cycle period within 5–10 s increased from 27.9% to 43.6%, indicating a 56% increase when horizontal baffles existed. It was proved by experiments that the mass-transfer coefficient increased by 31% and the mixing time decreased by 13% under a 0.06 vvm air aeration rate when horizontal baffles were used, and the algal biomass yield increased by ∼51% along with the decrease in the L/D cycle period when horizontal baffles were used.

Biological CO₂ elimination by photosynthetic microalgae is a sustainable way to mitigate CO₂ from flue gas and other sources.

CO2 capture from air by Chlorella vulgaris microalgae in an airlift photobioreactor

In this work, hydrodynamics and CO₂ biofixation study was conducted in an airlift bioreactor at the temperature of 30±2°C. The main objective of this work was to investigate the effect of high gas superficial velocity on CO₂ biofixation using Chlorella vulgaris microalgae and its growth. The study showed that Chlorella vulgaris in high input gas superficial velocity also had the ability to grow and remove the CO₂ by less than 80% efficiency.

Developing a water-circulating column photobioreactor for microalgal growth with low energy consumption

A water-circulating column photobioreactor (WCC-PBR) was developed to decrease bubble generation time and mixing time for growing microalgal biomass at low energy consumption. Bubble generation time was decreased by 60.4% and mixing time was decreased by 41.5% owing to an enhanced solution velocity with a water pump. Bubble residence time was decreased by 31.1% and mass transfer coefficient was decreased by 0.4% owing to a reduced distance between air aerator and solution surface. Microalgal growth rate was decreased by 12.7% from 128.9mg/Lday in an air-lifting column photobioreactor (ALC-PBR) to 112.6mg/Lday in a WCC-PBR because of the decrease in residence time of bubbles and an additional shear of cells in a water pump. However, total energy consumption of a WCC-PBR with an air compressor and a water pump was lower by 21.1% than that of an ALC-PBR with only an air compressor.