An experimental helical-tubular photobioreactor for continuous production of Nannochloropsis sp

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.

New Angled Twin-layer Porous Substrate Photobioreactors for Cultivation of Nannochloropsis oculata

An angled twin-layer porous substrate photobioreactor (TL-PSBR) using LED light was designed to cultivate Nannochloropsis oculata. Flocculation and sedimentation by modification of pH to 11 were determined as the optimal method for harvesting the N. oculata inoculum. The following optimised parameters were found: tilt angle 15°, Kraft 220 g m^-2 paper as substrate material, initial inoculum density of 12.5 g m^-2, 140 µmol photons m^-2 s^-1 light intensity, and a light/dark cycle of 6:6 (h). Test cultivation for 14 days was performed under optimised conditions. The total dried biomass standing crop was 75.5 g m^-2 growth area with an average productivity of 6.3 g m^-2 d^-1, the productivity per volume of used culture medium was 126.2 mg/L d^-1, total lipid content 21.9% (w/w), and the highest productivity of total lipids was 1.33 g m^-2 d^-1. The dry algal biomass contained 3% eicosapentaenoic acid (w/w), 3.7% palmitoleic acid (w/w), and 513 mg kg^-1 vitamin E. The optimisation of N. oculata cultivation on an angled TL-PSBR system yielded promising results, and applications for commercial products need to be further explored.

Design and applications of photobioreactors- a review

There has been increasing attention in recent years on the use of photobioreactors for various biotechnological applications, especially for the cultivation of microalgae. Photobioreactors-based production of photosynthetic microorganisms furnish several advantages as minimising toxicity and providing improved conditions. However, the designing and scaling-up of photobioreactors (PBRs) remain a challenge. Due to huge capital investment and operating cost, there is a deficiency of suitable PBRs for development of photosynthetic microorganisms on large-scale. It is, therefore, highly desirable to understand the current state-of-the-art PBRs, their advantages and limitations so as to classify different PBRs as per their most suited applications. This review provides a holistic overview of the discreet features of diverse PBR designs and their purpose in microalgae growth and biohydrogen production and also summarizes the recent development in use of hybrid PBRs to increase their working efficiency and overall economics of their operation for the production of value-added products.

Scale-up of a Fibonacci-Type Photobioreactor for the Production of Dunaliella salina

In this work, the previously proposed Fibonacci-type photobioreactor is scaled up and evaluated to produce Dunaliella salina. First, the composition of the culture medium was optimized to achieve maximal productivity. Next, the Fibonacci-type reactor was scaled up to 1250 L maintaining high solar radiation interception capacity of this type of reactor. Finally, the performance of the reactor for the production of green cells of Dunaliella salina at the environmental conditions prevailing in the Atacama Desert was evaluated. Data demonstrated that the proposed photobioreactor allows the temperature, pH and dissolved oxygen concentration to be maintained within the optimal ranges recommended for the selected strain. Both better exposure to solar radiation and photonic flow dilution avoids the use of cooling systems to prevent overheating under outdoor conditions. The system allows up to 60% more solar radiation to be intercepted than does the horizontal surface, likewise, allowing to maintain the pH efficiently through CO₂ injection and to keep the dissolved oxygen concentration in acceptable ranges, thanks to its adequate mass transfer capacity. The biomass concentration reached up to 0.96 g L^-1, three times higher than that obtained in a raceway reactor under the same environmental conditions, whereas productivity was up to 0.12 g L^-1 day (2.41 g m^-2 day). Maximum specific outdoor growth rates reached up to 0.17 day^-1. Undoubtedly, this technology scaled up constitutes a new type of photobioreactor for use at the industrial scale since it is capable of maximizing biomass productivity under high light conditions.

Helical tubular photobioreactor design using computational fluid dynamics

In this paper we present the design problem of helical tubular PhotoBioReactors (PBR) based on energy consumption minimization, using the radius of curvature for the cultivation of microalgae. Computational Fluid Dynamics (CFD) is used to design a configuration of the helical pipeline with minimum energy consumption. We determined how flow direction changes affect energy consumption. Additionally, it was found that the radius of curvature affects the pressure drop in the PBR’s pipe, so a cost function has been developed to solve an optimization problem seeking to obtain the optimum radius of curvature and a helical tubular PBR design with low pumping rates.

Algae as green energy reserve: Technological outlook on biofuel production

Depletion of fossil fuel sources and their emissions have triggered a vigorous research in finding alternative and renewable energy sources. In this regard, algae are being exploited as a third generation feedstock for the production of biofuels such as bioethanol, biodiesel, biogas, and biohydrogen. However, algal based biofuel does not reach successful peak due to the higher cost issues in cultivation, harvesting and extraction steps. Therefore, this review presents an extensive detail of deriving biofuels from algal biomass starting from various algae cultivation systems like raceway pond and photobioreactors and its bottlenecks. Evolution of biofuel feedstocks from edible oils to algae have been addressed in the initial section of the manuscript to provide insights on the different generation of biofuel. Different configuration of photobioreactor systems used to reduce contamination risk and improve biomass productivity were extensively discussed. Photobioreactor performance greatly relies on the conditions under which it is operated. Hence, the importance of such conditions alike temperature, light intensity, inoculum size, CO_2, nutrient concentration, and mixing in bioreactor performance have been described. As the lipid is the main component in biodiesel production, several pretreatment methods such as physical, chemical and biological for disrupting cell membrane to extract lipid were comprehensively reviewed and presented. This review article had put forth the recent advancement in the pretreatment methods like hydrothermal processing of algal biomasses using acid or alkali. Eventually, challenges and future dimensions in algal cultivation and pretreatment process were discussed in detail for making an economically viable algal biofuel.

Evaluation of colour temperatures in the cultivation of Dunaliella salina and Nannochloropsis oculata in the production of lipids and carbohydrates

The production of biofuels from microalgae is a promising and sustainable alternative. Its production is determined by the content of lipids and carbohydrates, which is different for each microalgae species and is affected by environmental factors, being lighting one of the principal determining their biochemical composition. The colour temperature (electromagnetic radiation and light spectrum) is a determining factor for the production of lipids and carbohydrates in microalgae. The aim of this assay was to evaluate the effect of three colour temperatures (6500, 10,000 and 20,000 °K) on the biomass (cel mL^-1), biomass production and productivity (g L^-1 and g L^-1 day^-1), lipid and carbohydrate content (%), lipid and carbohydrate production and productivity (mg L^-1 and mg L^-1 day^-1), composition and content of fatty acids (%) in two microalgae species: Dunaliella salina and Nannochloropsis oculata. The highest cell density was observed for N. oculata in stationary phase in the control (83.93 × 106 cel mL^-1). However, higher lipid content was obtained in D. salina in stationary phase at 10,000 °K (80%), while N. oculata showed 67% at 6500 °K. The highest carbohydrate content was 25% in stationary phase for D. salina at 20,000 °K. Regarding the production of lipids, D. salina reached a maximum of 523 mg L^-1 in exponential phase at 6500 and 10,000 °K. The highest carbohydrate production was 38 mg L^-1 for D. salina in exponential phase at 20,000 °K. In both microalgae, 15 different fatty acids were identified; the most abundant was palmitic acid with 35.8% for N. oculata in stationary phase at 10,000 °K, while D. salina showed 67% of polyunsaturated fatty acids in exponential phase at 6500 °K. In conclusion, the ideal colour temperature for microalgae culture to obtain biofuels should be based on the biomolecule of interest, being necessary to individually evaluate for each species.

Investigation of Chlorella vulgaris UTEX 265 Cultivation under Light and Low Temperature Stressed Conditions for Lutein Production in Flasks and the Coiled Tree Photo-Bioreactor (CTPBR)

Lutein has an increasing share in the pharmaceutical and nutraceutical market due to its benefits to eye health. Microalgae may be a potential source for lutein production while the expense limits the commercialization. In this study, a coiled tubular tree photobioreactor (CTPBR) design was investigated for cultivating the cold tolerant microalgae Chlorella vulgaris UTEX 265 under various conditions for lutein production. The influence and interaction of light irradiance strength, lighting cycle, and temperature on microalgae and lutein production efficiency at low temperature range were also studied in flasks via response surface method (RSM). The results demonstrated that 14 h day-light, 120 μmol photons m^-2 s^-1, and 10 °C was the optimal condition for algae growth and lutein production at low temperature experimental ranges. C. vulgaris UTEX 265 showed good potential to produce lutein in cold weather, and the optimum lutein production was contrary to the specific lutein content but corresponds to the trend of optimum growth. Additionally, fast growth (μ = 1.50 day^-1) and good lutein recovery (11.98 mg g^-1 day^-1) in CTPBR were also achieved at the low irradiance stress condition and the low temperature photo-inhibition conditions.

Lipid Production from Nannochloropsis

Microalgae are sunlight-driven green cell factories for the production of potential bioactive products and biofuels. Nannochloropsis represents a genus of marine microalgae with high photosynthetic efficiency and can convert carbon dioxide to storage lipids mainly in the form of triacylglycerols and to the ω-3 long-chain polyunsaturated fatty acid eicosapentaenoic acid (EPA). Recently, Nannochloropsis has received ever-increasing interests of both research and public communities. This review aims to provide an overview of biology and biotechnological potential of Nannochloropsis, with the emphasis on lipid production. The path forward for the further exploration of Nannochloropsis for lipid production with respect to both challenges and opportunities is also discussed.

Multi-Wavelength Based Optical Density Sensor for Autonomous Monitoring of Microalgae

A multi-wavelength based optical density sensor unit was designed, developed, and evaluated to monitor microalgae growth in real time. The system consisted of five main components including: (1) laser diode modules as light sources; (2) photodiodes as detectors; (3) driver circuit; (4) flow cell; and (5) sensor housing temperature controller. The sensor unit was designed to be integrated into any microalgae culture system for both real time and non-real time optical density measurements and algae growth monitoring applications. It was shown that the sensor unit was capable of monitoring the dynamics and physiological changes of the microalgae culture in real-time. Algae biomass concentration was accurately estimated with optical density measurements at 650, 685 and 780 nm wavelengths used by the sensor unit. The sensor unit was able to monitor cell concentration as high as 1.05 g·L⁻¹ (1.51 × 10⁸ cells·mL⁻¹) during the culture growth without any sample preparation for the measurements. Since high cell concentrations do not need to be diluted using the sensor unit, the system has the potential to be used in industrial microalgae cultivation systems for real time monitoring and control applications that can lead to improved resource use efficiency.

Monitoring of Microalgal Processes

Process monitoring, which can be defined as the measurement of process variables with the smallest possible delay, is combined with process models to form the basis for successful process control. Minimizing the measurement delay leads inevitably to employing online, in situ sensors where possible, preferably using noninvasive measurement methods with stable, low-cost sensors. Microalgal processes have similarities to traditional bioprocesses but also have unique monitoring requirements. In general, variables to be monitored in microalgal processes can be categorized as physical, chemical, and biological, and they are measured in gaseous, liquid, and solid (biological) phases. Physical and chemical process variables can be usually monitored online using standard industrial sensors. The monitoring of biological process variables, however, relies mostly on sensors developed and validated using laboratory-scale systems or uses offline methods because of difficulties in developing suitable online sensors. Here, we review current technologies for online, in situ monitoring of all types of process parameters of microalgal cultivations, with a focus on monitoring of biological parameters. We discuss newly introduced methods for measuring biological parameters that could be possibly adapted for routine online use, should be preferably noninvasive, and are based on approaches that have been proven in other bioprocesses. New sensor types for measuring physicochemical parameters using optical methods or ion-specific field effect transistor (ISFET) sensors are also discussed. Reviewed methods with online implementation or online potential include measurement of irradiance, biomass concentration by optical density and image analysis, cell count, chlorophyll fluorescence, growth rate, lipid concentration by infrared spectrophotometry, dielectric scattering, and nuclear magnetic resonance. Future perspectives are discussed, especially in the field of image analysis using in situ microscopy, infrared spectrophotometry, and software sensor systems.

Effects of light and circadian clock on growth and chlorophyll accumulation of Nannochloropsis gaditana

Circadian clocks synchronize various physiological, metabolic and developmental processes of organisms with specific phases of recurring changes in their environment (e.g. day and night or seasons). Here, we investigated whether the circadian clock plays a role in regulation of growth and chlorophyll (Chl) accumulation in Nannochloropsis gaditana, an oleaginous marine microalga which is considered as a potential feedstock for biofuels and for which a draft genome sequence has been published. Optical density (OD) of N. gaditana culture was monitored at 680 and 735 nm under 12:12 h or 18:6 h light-dark (LD) cycles and after switching to continuous illumination in photobioreactors. In parallel, Chl fluorescence was measured to assess the quantum yield of photosystem II. Furthermore, to test if red- or blue-light photoreceptors are involved in clock entrainment in N. gaditana, some of the experiments were conducted by using only red or blue light. Growth and Chl accumulation were confined to light periods in the LD cycles, increasing more strongly in the first half than in the second half of the light periods. After switching to continuous light, rhythmic oscillations continued (especially for OD680 ) at least in the first 24 h, with a 50% decrease in the capacity to grow and accumulate Chl during the first subjective night. Pronounced free-running oscillations were induced by blue light, but not by red light. In contrast, the photosystem II quantum yield was determined by light conditions. The results indicate interactions between circadian and light regulation of growth and Chl accumulation in N. gaditana.

GrowingChlorella vulgarisin Photobioreactor by Continuous Process Using Concentrated Desalination: Effect of Dilution Rate on Biochemical Composition

Desalination wastewater, which contains large amount of salt waste, might lead to severely environmental pollution. This study evaluated the effect of dilution rate (0.1≤D≤0.3day−1) on microalgal biomass productivity, lipid content, and fatty acid profile under steady-state condition ofChlorella vulgarissupplemented with concentrated desalination. Continuous culture was conducted for 55 days. Results show that the biomass productivity (Px) varied from 57 to 126 mg L−1 d−1(dry mass) when the dilution rate ranged from 0.1 to 0.3 day−1. At lowest dilution rate (D=0.1day−1), the continuous culture regime ensured the highest values of maximum biomass concentration (Xm=570±20 mL−1) and protein content (52%). Biomass lipid content was an increasing function ofD. The most abundant fatty acids were the palmitic (25.3±0.6%) atD=0.1day−1and the gamma-linolenic acid (23.5±0.1%) atD=0.3day−1ones. These fatty acids present 14 to 18 carbons in the carbon chain, being mainly saturated and polyunsaturated, respectively. Overall, the results show that continuous culture is a powerful tool to investigate the cell growth kinetics and physiological behaviors of the algae growing on desalination wastewater.

Carbon dioxide bio-fixation and wastewater treatment via algae photochemical synthesis for biofuels production

Utilizing the energy, nutrients and CO₂held within residual waste materials to provide all necessary inputs except for sunlight, the cultivation of algae becomes a closed-loop engineered ecosystem. Developing this green biotechnology is a tangible step towards a waste-free sustainable society.

Radiation and optical properties of Nannochloropsis oculata grown under different irradiances and spectra

This paper reports accurate measurements of the radiation characteristics and optical properties of Nannochloropsis oculata in the photosynthetically active radiation (PAR) region. These marine microalgae were grown in 2 cm thick culture bottles with vented caps exposed, on one side, to either white fluorescent light bulbs or red LEDs emitting at 630 nm. The illuminance varied from 2000 to 10,000 lux. The microalgae average equivalent diameter ranged from 2.52 to 2.63 μm. Their radiation characteristics and optical properties were statistically identical over most of the PAR region. Other N. oculata grown with 2 vol.% CO2 injection in 1cm thick flat bottles exposed to light from both sides reached a significantly larger mass concentration and featured lower pigment concentration and smaller absorption cross-sections. This was due to nutrient limited growth conditions. The refraction index was independent of illuminance, spectrum, and growth conditions and featured resonance at wavelengths corresponding to absorption peaks.

On-line monitoring of large cultivations of microalgae and cyanobacteria

Large cultivations of microalgae will benefit from on-line monitoring to achieve process control and improved productivity. This monitoring requires reliable sensors for on-line, in situ measurement of both physicochemical and biological process variables. Although standard industrial sensors can be used for many physicochemical variables, monitoring methods for most biological quantities rely on sensors that are currently suitable only for laboratory scale or off-line use. Here, we review these methods and discuss new approaches that could be adapted. We suggest that these new methods should be noninvasive and based on approaches that have already been applied to other bioprocesses; examples discussed here are in situ microscopy, flow cytometry (FC), IR spectroscopy, and software sensors.

A novel potential source of β-carotene: Eustigmatos cf. polyphem (Eustigmatophyceae) and pilot β-carotene production in bubble column and flat panel photobioreactors

Carotenoids profile of the unicellular Eustigmatos cf. polyphem (Eustigmatophyceae) and β-carotene production of the microalga in bubble column and large flat panel bioreactors were studied. The microalga which contained β-carotene, violaxanthin and vaucheriaxanthin as the major carotenoids accumulated large amount of β-carotene. The β-carotene production of this microalga in the bubble column bioreactor was considerable, with the maximum intracellular β-carotene content reaching 60.76 mg g(-1), biomass reaching 9.2 g L(-1), and β-carotene yield up to 470.2 mg L(-1). The β-carotene productions in two large flat panel bioreactors were relatively lower, whereas over 100 mg β-carotene L(-1) was achieved. Besides, high light intensity helped to accumulate intracellular β-carotene and biomass. Deficient nitrate supply inhibited biomass growth, though it helped to accumulate β-carotene. Our results first proved that E. cf. polyphem was a potential source and producer of β-carotene, making it an interesting subject for further β-carotene study or commercial exploration.

An overview of algae biofuel production and potential environmental impact

Algae are among the most potentially significant sources of sustainable biofuels in the future of renewable energy. A feedstock with virtually unlimited applicability, algae can metabolize various waste streams (e.g., municipal wastewater, carbon dioxide from industrial flue gas) and produce products with a wide variety of compositions and uses. These products include lipids, which can be processed into biodiesel; carbohydrates, which can be processed into ethanol; and proteins, which can be used for human and animal consumption. Algae are commonly genetically engineered to allow for advantageous process modification or optimization. However, issues remain regarding human exposure to algae-derived toxins, allergens, and carcinogens from both existing and genetically modified organisms (GMOs), as well as the overall environmental impact of GMOs. A literature review was performed to highlight issues related to the growth and use of algal products for generating biofuels. Human exposure and environmental impact issues are identified and discussed, as well as current research and development activities of academic, commercial, and governmental groups. It is hoped that the ideas contained in this paper will increase environmental awareness of issues surrounding the production of algae and will help the algae industry develop to its full potential.

Effects of reduced diameter of bag cultures on content of essential fatty acids and cell density in a continuous algal production system

Cell density and fatty acid (FA) content of Pavlova lutheri and Chaetoceros muelleri were analysed in a continuous algal production system (250-L bags) with reduced diameter. The cell density and FA content and composition in the algal production system were determined in replicate bags over a period of 5 weeks. The results showed that the cell density and essential FAs increased during the experiment for both species. After 5 weeks the mean cell numbers had increased to 6.0 ± 0.3 × 10(6) cells mL(-1) in the P. lutheri bags and 6.0 ± 0.4 × 10(6) cells mL(-1) in the C. muelleri bags. The content of total FAs increased significantly (p < 0.05) in all of the bags during the experiment. At the end of the experiment the mean total FA content were 2.7 ± 0.3 pg cell(-1) in the P. lutheri bags and 1.8 ± 0.1 pg cell(-1) in the C. muelleri bags. Maximum total FA content registered was 3.0 pg cell(-1) in one of the P. lutheri bags. The content of the essential FAs (ARA, EPA, DHA) increased over time in both of the species. At the end of the experiment the content of EPA (0.6 ± 0.1 pg cell(-1)) and DHA (0.3 ± 0.0 pg cell(-1)) were highest in the P. lutheri bags, while ARA (0.1 ± 0.0 pg cell(-1)) was highest in C. muelleri. EPA and DHA constituted 22% and 11%, respectively, of total FA content in P. lutheri, while ARA constituted 6% of total FA content in C. muelleri. The results from this experiment indicate that flagellates such as P. lutheri perform better in narrow bags with improved light conditions, while diatoms like C. muelleri perform better in wider bags under light limitation. Implications for bivalve hatcheries are discussed. ELECTRONIC SUPPLEMENTARY MATERIAL: The online version of this article (doi:10.1007/s10811-011-9655-6) contains supplementary material, which is available to authorized users.