Scale-up of photo-bioreactors for microalgae cultivation by π-theorem

Interchangeable modular design and operation of photo-bioreactors for Chlorella vulgaris cultivation towards a zero-waste biorefinery

This study explores diverse cultivation modes for Chlorella vulgaris within a biorefinery at pilot scale that produces both biodiesel by transesterification of waste frying oils and syngas by gasification of organic wood waste. Given microalgae's comparatively modest biofuel yield relative to principal biorefinery products, the microalgae cultivation process is designed on the biofuels production rates. Liquid and gaseous waste streams are recycled inside the biorefinery: crude glycerol is mixed with wood to enhance the quality of syngas, wastewater is fed to microalgae so as flue gas. Also, the oil extracted from microalgae contributes to produce biodiesel and the waste cells are gasified. Considering that the optimal fit for each cultivation mode varies with the shape of the reactor, we propose a modular approach to assemble them in batteries of tubular, bubble flow, and airlift reactors, and present an operating design criterion that can fulfill the mass balance of the plant by adding/transforming the number of units inside the different batteries. Methods to adjust the operating conditions and control the operating parameters are also discussed. The designed configurations were operated recycling nominal waste streams of about 30 L d-1 of wastewater and 90 Nm3 h-1 of flue gas. Results confirm that the most advantageous one, in terms of volume per recycled waste streams, is a battery of 16 airlift reactors, operating in mixotrophic mode, with growing rate of 0.427 d-1, yield of 3.06, glycerol conversion 39 %, CO2 removal 64 % of inlet 6-10 %(mol) concentration. The same nominal waste streams can also be managed by 40 tubular reactors in almost heterotrophic conditions coupled with 12 bubble columns in autotrophic conditions; working respectively at growing rates of 0.395 d-1 and 0.362 d-1 and yields of 2.94 and 2.84. The battery of tubular reactors reached a glycerol conversion of 45 % and the array of bubble columns removed about 51 % of inlet 12-20 %(mol) CO2 concentration. A complete comparison is reported also in terms of dimensionless numbers and pumping/mixing requirements.

Conceptual Design of an Autotrophic Multi-Strain Microalgae-Based Biorefinery: Preliminary Techno-Economic and Life Cycle Assessments

Microalgae represent a promising solution in addressing the impacts associated with the current agricultural and manufacturing practices which are causing irreparable environmental damage. Microalgae have considerable biosynthetic potential, being a rich source of lipids, proteins, and high-value compounds. Under the scope of the H2020-BBI MULTI-STR3AM project, an innovative large-scale production system of valuable commodities for the food, feed, and fragrance sectors is being developed on the basis of microalgae, reducing costs, increasing the scale of production, and boosting value chain sustainability. In this work, we aimed to create a process model that can mimic an industrial plant to estimate mass and energy balances, optimize scheduling, and calculate production costs for a large-scale plant. Three autotrophic microalgae strains (Nannochloropsis sp., Dunaliella sp. and Spirulina sp.) were considered for this assessment, as well as the use of locally sourced CO2 (flue gas). The developed process model is a useful tool for obtaining the data required for techno-economic analysis (TEA) and life cycle assessment (LCA) of industrial biorefinery-based processes. Nannochloropsis sp. was the most economic option, whereas Dunaliella sp. was the most expensive strain to produce due to its lower productivity. Preliminary environmental assessments of the climate change impact category revealed that water recirculation and the use of flue gas could lead to values of 5.6, 10.6, and 9.2 kgCO2eq·kgAFDW−1 for Nannochloropsis sp., Dunaliella sp., and Spirulina sp., respectively, with electricity and NaCl as the main contributors. The obtained data allow for the quantification of the production costs and environmental impacts of the microalgal biomass fractions produced, which will be fundamental for future comparison studies and in determining if they are higher or lower than those of the replaced products. The process model developed in this work provides a useful tool for the evaluation and optimization of large-scale microalgae production systems.

Data-driven and validated dimensional analysis for rational scale-up of a dual-chamber microbial fuel cell system for water-energy nexus exploitation

Mathematical modelling of microbial fuel cells (MFC) facilitates their scale-up by maintaining dimensionless parameters across reactor volumes for consistent performance. This study developed data-driven correlations to predict areal power density for a batch-fed dual-chamber MFC using hybridised first-principle mechanistic model and Buckingham's Pi theorem. The established correlations were validated using experimentally-derived data for pre-enriched electroactive biofilm from mixed cultures. The biochemical model parameters are infilled with stoichiometric and thermodynamics estimations. Results showed that the correlations using logistic kinetics (Nash-Sutcliffe Efficiency, NSE = 0.59) outperformed Monod kinetics (NSE = 0.52) as the latter was not suitable for representing the first-order biochemical kinetics under limited substrate conditions. Sensitivity analysis on varying pH and bicarbonate concentration improved model predictions by ± 50%, though relative absolute error was ± 20% due to inherent error of estimated biochemical parameters. The application of hybridised approach for modelling MFC provides renewed perspectives for their rational design and scale-up applications.

Industrial CO2 Capture by Algae: A Review and Recent Advances

The problem of global warming and the emission of greenhouse gases is already directly affecting the world’s energy. In the future, the impact of CO2 emissions on the world economy will constantly grow. In this paper, we review the available literature sources on the benefits of using algae cultivation for CO2 capture to decrease CO2 emission. CO2 emission accounts for about 77% of all greenhouse gases, and the calculation of greenhouse gas emissions is 56% of all CO2 imports. As a result of the study of various types of algae, it was concluded that Chlorella sp. is the best at capturing CO2. Various methods of cultivating microalgae were also considered and it was found that vertical tubular bioreactors are emerging. Moreover, for energy purposes, thermochemical methods for processing algae that absorb CO2 from flue gases were considered. Of all five types of thermochemical processes for producing synthesis gas, the most preferred method is the method of supercritical gasification of algae. In addition, attention is paid to the drying and flocculation of biofuels. Several different experiments were also reviewed on the use of flue gases through the cultivation of algae biomass. Based on this literature review, it can be concluded that microalgae are a third generation biofuel. With the absorption of greenhouse gases, the growth of microalgae cultures is accelerated. When a large mass of microalgae appears, it can be used for energy purposes. In the results, we present a plan for further studies of microalgae cultivation, a thermodynamic analysis of gasification and pyrolysis, and a comparison of the results with other biofuels and other algae cultures.

Mass Cultivation of Microalgae: I. Experiences with Vertical Column Airlift Photobioreactors, Diatoms and CO2 Sequestration

From 2015 to 2021, we optimized mass cultivation of diatoms in our own developed vertical column airlift photobioreactors using natural and artificial light (LEDs). The project took place at the ferrosilicon producer Finnfjord AS in North Norway as a joint venture with UiT—The Arctic University of Norway. Small (0.1–6–14 m3) reactors were used for initial experiments and to produce inoculum cultures while upscaling experiments took place in a 300 m3 reactor. We here argue that species cultivated in reactors should be large since biovolume specific self-shadowing of light can be lower for large vs. small cells. The highest production, 1.28 cm3 L−1 biovolume (0.09–0.31 g DW day−1), was obtained with continuous culture at ca. 19% light utilization efficiency and 34% CO2 uptake. We cultivated 4–6 months without microbial contamination or biofouling, and this we argue was due to a natural antifouling (anti-biofilm) agent in the algae. In terms of protein quality all essential amino acids were present, and the composition and digestibility of the fatty acids were as required for feed ingredients. Lipid content was ca. 20% of ash-free DW with high EPA levels, and omega-3 and amino acid content increased when factory fume was added. The content of heavy metals in algae cultivated with fume was well within the accepted safety limits. Organic pollutants (e.g., dioxins and PCBs) were below the limits required by the European Union food safety regulations, and bioprospecting revealed several promising findings.

Evaluating hydrodynamics in a bioreactor with liquid phase dispersion in the gas phase

Bioreactors are used in many biochemical industries to produce commercial life products such as medicines, enzymes, perfumes, paints and antibiotics. In the presented study, a specially shaped bioreactor has been designed, built and operated to increase the mass transfer coefficient. The constructed bioreactor, according to type of microorganisms, can provide high amounts of oxygen or carbon dioxide. Moreover, the manuscript was aimed at investigating the hydrodynamic properties of the bioreactor. The bioreactor was constructed from three parts including shower in upper part, middle section for mass transfer and bottom section as a reservoir. Liquid flow rate, shower holes diameter, aeration velocity and the middle part height of the bioreactor have been studied as factors influencing the hydrodynamics. The results showed that the highest mass transfer coefficient was 30.1 1/h which was achieved when the liquid flow rate, the shower holes diameter, aeration velocity and middle part height of the bioreactor were 280 mL/min, 2 mm, 0.03 vvm and 60 cm, respectively.