Continuous microalgae recovery using electrolysis with polarity exchange

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.

A Novel Salt-Bridge Electroflocculation Technology for Harvesting Microalgae

Microalgae biomass, as a promising alternative feedstock, can be refined into biodiesel, pharmaceutical, and food productions. However, the harvesting process for quality biomass still remains a main bottleneck due to its high energy demand. In this study, a novel technique integrating alkali-induced flocculation and electrolysis, named salt-bridge electroflocculation (SBEF) with non-sacrificial carbon electrodes is developed to promote recovery efficiency and cost savings. The results show that the energy consumption decreased to 1.50 Wh/g biomass with a high harvesting efficiency of 90.4% under 300 mA in 45 min. The mean particle size of algae flocs increased 3.85-fold from 2.75 to 10.59 µm, which was convenient to the follow-up processing. Another major advantage of this method is that the salt-bridge firmly prevented cells being destroyed by the anode’s oxidation and did not bring any external contaminants to algal biomass and flocculated medium, which conquered the technical defects in electro-flocculation. The proposed SBEF technology could be used as a low cost process for efficient microalgae harvest with high quality biomass.

Recent progress in flocculation, dewatering, and drying technologies for microalgae utilization: Scalable and low-cost harvesting process development

Microalgal research has made significant progress in terms of the high-value-added industrial application of microalgal biomass and its derivatives. However, cost-effective techniques for producing, harvesting, and processing microalgal biomass on a large scale still need to be fully explored in order to optimize their performance and achieve commercial robustness. In particular, technologies for harvesting microalgae are critical in the practical process as they require excessive energy and equipment costs. This review focuses on microalgal flocculation, dewatering, and drying techniques and specifically covers the traditional approaches and recent technological progress in harvesting microalgal biomass. Several aspects, including the characteristics of the target microalgae and the type of final value-added products, must be considered when selecting the appropriate harvesting technique. Furthermore, considerable aspects and possible future directions in flocculation, dewatering, and drying steps are proposed to develop scalable and low-cost microalgal harvesting systems.

Mass cultivation and harvesting of microalgal biomass: Current trends and future perspectives

Microalgae are unicellular photosynthetic organisms capable of producing high-value metabolites like carbohydrates, lipids, proteins, polyunsaturated fatty acids, vitamins, pigments, and other high-value metabolites. Microalgal biomass gained more interest for the production of nutraceuticals, pharmaceuticals, therapeutics, food supplements, feed, biofuel, bio-fertilizers, etc. due to its high lipid and other high-value metabolite content. Microalgal biomass has the potential to convert trapped solar energy to organic materials and potential metabolites of nutraceutical and industrial interest. They have higher efficiency to fix carbon dioxide (CO₂) and subsequently convert it into biomass and compounds of potential interest. However, to make microalgae a potential industrial candidate, cost-effective cultivation systems and harvesting methods for increasing biomass yield and reducing the cost of downstream processing have become extremely urgent and important. In this review, the current development in different microalgal cultivation systems and harvesting methods has been discussed.

A critical review on different harvesting techniques for algal based biodiesel production

The fuels retrieved from renewable sources which are usually employed as both carbon and energy sources are termed as neutral based biofuels. The most promising feedstock from renewable sources with great potentiality in contributing to the inclining energy demand is microalgae. These microalgae can be harnessed readily in terms of obtaining qualitative biodiesel with greater energy consumption under limited operational cost. The process of harvesting or dewatering microalgae could be carried under single or sequential combinations of operations. The major drawback of harvesting such as huge operational cost could be lowered by increasing the level of automation than cost of investments. The present review concentrates and explores on the techno-economic analysis of the microalgal harvesting and dewatering processes on a large scale. Along with these advanced techniques enclosing the utilization of nanoparticles for harvesting has also been explored. And it also adds with the impacts of concerning facts on energy consumption, processing cost and recovery of resources during harvesting.

Microalgal Biomass Generation via Electroflotation: A Cost-Effective Dewatering Technology

Microalgae are an excellent source of bioactive compounds for the production of a wide range of vital consumer products in the biofuel, pharmaceutical, food, cosmetics, and agricultural industries, in addition to huge upstream benefits relating to carbon dioxide biosequestration and wastewater treatment. However, energy-efficient, cost-effective, and scalable microalgal technologies for commercial-scale applications are limited, and this has significantly impacted the full-scale implementation of microalgal biosystems for bioproduct development, phycoremediation, and biorefinery applications. Microalgae culture dewatering continues to be a major challenge to large-scale biomass generation, and this is primarily due to the low cell densities of microalgal cultures and the small hydrodynamic size of microalgal cells. With such biophysical characteristics, energy-intensive solid–liquid separation processes such as centrifugation and filtration are generally used for continuous generation of biomass in large-scale settings, making dewatering a major contributor to the microalgae bioprocess economics. This article analyzes the potential of electroflotation as a cost-effective dewatering process that can be integrated into microalgae bioprocesses for continuous biomass production. Electroflotation hinges on the generation of fine bubbles at the surface of an electrode system to entrain microalgal particulates to the surface. A modification of electroflotation, which combines electrocoagulation to catalyze the coalescence of microalgae cells before gaseous entrainment, is also discussed. A technoeconomic appraisal of the prospects of electroflotation compared with other dewatering technologies is presented.

Effect of the induced dielectrophoretic force on harvesting of marine microalgae (Tetraselmis sp.) in electrocoagulation

In this study, a new electrocoagulation electrode configuration has been investigated in order to induce dielectrophoretic (DEP) force for the enhanced harvesting of marine microalgae (Tetraselmis sp.). Asymmetrical aluminum electrodes with an alternative current power supply were used. The impact of electrode configuration, current density and electrolysis time were evaluated. A maximum algal harvesting efficiency of 90.9% was achieved using 7.1 mA/cm² current density and 10 min electrolysis time. The energy consumption was found to be 4.62 kWh/kg of microalgae. The major significance of using the new electrode configuration was found in the aluminum content in the harvested biomass which decreased by 52% compared to the conventional symmetrical electrocoagulation electrodes.

Flocculation Harvesting Techniques for Microalgae: A Review

Microalgae have been considered as one of the most promising biomass feedstocks for various industrial applications such as biofuels, animal/aquaculture feeds, food supplements, nutraceuticals, and pharmaceuticals. Several biotechnological challenges associated with algae cultivation, including the small size and negative surface charge of algal cells as well as the dilution of its cultures, need to be circumvented, which increases the cost and labor. Therefore, efficient biomass recovery or harvesting of diverse algal species represents a critical bottleneck for large-scale algal biorefinery process. Among different algae harvesting techniques (e.g., centrifugation, gravity sedimentation, screening, filtration, and air flotation), the flocculation-based processes have acquired much attention due to their promising efficiency and scalability. This review covers the basics and recent research trends of various flocculation techniques, such as auto-flocculation, bio-flocculation, chemical flocculation, particle-based flocculation, and electrochemical flocculation, and also discusses their advantages and disadvantages. The challenges and prospects for the development of eco-friendly and economical algae harvesting processes have also been outlined here.

A rapid inoculation method for microalgae biofilm cultivation based on microalgae-microalgae co-flocculation and zeta-potential adjustment

Due to the small size, similar density to water, cells inoculating onto the solid carrier is a major challenge for microalgae biofilm cultivation. To reduce biofilm inoculation time, A. falcatus with long stripe were chosen as the bond linking with the main microalgae cells forming microalgae-microalgae co-flocculation by bridging and twining. The optimal matching species were S. obliquus and A. falcatus with the volume ratio of 4-1. By changing the zeta-potential of the microalgae-microalgae co-flocculation to positive and negative through pH regulating, the inoculation time was significantly shorted from 4 h to 1.5 min due to the charge neutralization. Fortunately, the added A. falcatus and pH regulation has no negative effects on biofilm growth. Inversely, the porous microstructure of microalgae-microalgae co-flocculation improve the transfer efficiency of nutrients, resulting a 90.15% increase on biomass productivity (229.15 g m^-2) comparing to pure microalgae species.

A novel electro-coagulation-Fenton for energy efficient cyanobacteria and cyanotoxins removal without chemical addition

Harmful cyanobacterial bloom is a serious threat to global aquatic ecology and drinking water safety. Electro-Fenton (EF) has emerged as an efficient process for cyanobacteria and cyanotoxins removal, but high consumption of energy and chemicals remain a major bottleneck. This study presents a novel convertible three-electrodes Electro-Coagulation-Fenton process for cyanobacteria and cyanotoxins removal with low energy consumption and no chemicals addition. We for the first time demonstrated the freely alternating between Electrocoagulation (EC) and EF by switching electrodes. The optimal aerated EC was operated at pH 8 and 100 mA to remove 91 ± 2% of cyanobaterial cells and 15% of Microcystins (MCs). Coagulants generated in EC were adsorbed on cyanobacterial cells to form a protect layer against algae disruption and cyanotoxins releasing. Residual MCs and cyanobaterial cells were completely mineralized by EF at 28 mA with iron ions and H₂O₂ generated in-situ. Compare to traditional EF, the optimal Electro-Coagulation-Fenton process increased total organic carbon (TOC) removal efficiency by 30%, yet energy consumption reduced up to 92%. The novel Electro-Coagulation-Fenton process is a promising technology for the efficient treatment of the mixture of suspended solid pollutants and persistent organic pollutants in one system with low energy consumption.

A continuous flocculants-free electrolytic flotation system for microalgae harvesting

High harvesting cost and reusing of post-harvest water are the major challenges in commercial production of microalgae. In this work, a flocculants-free electrolytic flotation harvest process was investigated. The electrode design and materials were evaluated in terms of harvesting efficiency. Stainless steel as the cathode and carbon as the anode were selected based on the harvesting efficiency data and non-sacrificial feature for construction of a pilot scale harvesting system. In the pilot scale experiments, 23.72g/h biomass yield was achieved at the power consumption of 2.73kWh/kg. With the advantages of no chemical flocculent contamination and relatively low energy requirement, this continuous system is promising for food or feed applications.

A novel electroporation system for efficient molecular delivery into Chlamydomonas reinhardtii with a 3-dimensional microelectrode

Electroporation is one of the most widely used transfection methods because of its high efficiency and convenience among the various transfection methods. Previous micro-electroporation systems have some drawbacks such as limitations in height and design, time-consuming and an expensive fabrication process due to technical constraints. This study fabricates a three dimensional microelectrode using the 3D printing technique. The interdigitated microstructure consisting of poly lactic acid was injected by a 3D printer and coated with silver and aluminum with a series of dip-coatings. With the same strength of electric field (V cm⁻¹), a higher efficiency for molecular delivery and a higher cellular viability are achieved with the microelectrode than with a standard cuvette. In addition, this study investigates chemicophysical changes such as Joule heating and dissolved metal during electroporation and showed the micro-electroporation system had less chemicophysical changes. It was concluded that the proposed micro-electroporation system will contribute to genetic engineering as a promising delivery tool, and this combination of 3D printing and electroporation has many potential applications for diverse designs or systems.

Advanced treatment of residual nitrogen from biologically treated coke effluent by a microalga-mediated process using volatile fatty acids (VFAs) under stepwise mixotrophic conditions

This work describes the development of a microalga-mediated process for simultaneous removal of residual ammonium nitrogen (NH4(+)-N) and production of lipids from biologically treated coke effluent. Four species of green algae were tested using a sequential mixotrophic process. In the first phase-CO2-supplied mixotrophic condition-all microalgae assimilated NH4(+)-N with no evident inhibition. In second phase-volatile fatty acids (VFAs)-supplied mixotrophic condition-removal rates of NH4(+)-N and biomass significantly increased. Among the microalgae used, Arctic Chlorella sp. ArM0029B had the highest rate of NH4(+)-N removal (0.97 mg/L/h) and fatty acid production (24.9 mg/L/d) which were 3.6- and 2.1-fold higher than those observed under the CO2-supplied mixotrophic condition. Redundancy analysis (RDA) indicated that acetate and butyrate were decisive factors for increasing NH4(+)-N removal and fatty acid production. These results demonstrate that microalgae can be used in a sequential process for treatment of residual nitrogen after initial treatment of activated sludge.

An integrated process for microalgae harvesting and cell disruption by the use of ferric ions

In this study, a simultaneous process of harvesting biomass and extracting crude bio-oil was attempted from wet microalgae biomass using FeCl3 and Fe2(SO4)3 as both coagulant and cell-disrupting agent. A culture solution of Chlorella sp. KR-1 was firstly concentrated to 20 g/L and then proceeded for cell disruption with the addition of H2O2. Optimal dosage were 560 and 1060 mg/L for FeCl3 and Fe2(SO4)3, showing harvesting efficiencies of more than 99%. Optimal extraction conditions were identified via the response surface method (RSM), and the extraction yield was almost the same at 120 °C for both iron salts but FAME compositions after transesterification was found to be quite different. Given iron salts were a reference coagulant in water treatment in general and microalgae harvesting in particular, the present approach of using it for harvesting and oil-extraction in a simultaneous manner can serve as a practical route for the microalgae-derived biodiesel production.

Current progress and future prospect of microalgal biomass harvest using various flocculation technologies

Microalgae have been extensively studied for the production of various valuable products. Application of microalgae for the production of renewable energy has also received increasing attention in recent years. However, high cost of microalgal biomass harvesting is one of the bottlenecks for commercialization of microalgae-based industrial processes. Considering harvesting efficiency, operation economics and technological feasibility, flocculation is a superior method to harvest microalgae from mass culture. In this article, the latest progress of various microalgal cell harvesting methods via flocculation is reviewed with the emphasis on the current progress and prospect in environmentally friendly bio-based flocculation. Harvesting microalgae through bio-based flocculation is a promising component of the low-cost microalgal biomass production technology.

Facile sand enhanced electro-flocculation for cost-efficient harvesting of Dunaliella salina

Energy consumption and water resource in the cultivation and harvesting steps still need to be minimized for the popularization of the microalgae-based products. An efficient electro-flocculation method for harvesting Dunaliella Salina integrated with local sand has been successfully applied. Sand was effective for speeding up the processes of flocculation and sedimentation of algal flocs and the electrolytic hydroxides was essential to bridge the sand and small flocs into large dense flocs. The maximal recovery effective improved from 95.13% in 6min to 98.09% in 4.5min and the optimal electrical energy consumption decreased 51.03% compared to conventional electro-flocculation in a laboratory ambient condition. Furthermore, reusing the flocculated medium in cultivation of the D. Salina with nitrogen supplemented performed no worse than using fresh medium. This sand enhanced electro-flocculation (SEF) technology provides a great potential for saving time and energy associated with improving microalgae harvesting.

Evaluation of operating conditions for sustainable harvesting of microalgal biomass applying electrochemical method using non sacrificial electrodes

The efficient harvesting of microalgae is considered to be one of the challenging steps of algal biofuel production and a key factor limiting the commercial use of microalgae. To overcome the limitation of metallic electrodes depletion, the application of non-sacrificial electrode was investigated for the electrochemical harvesting (ECH) of microalgae. The effect of applied current, addition of electrolyte and initial pH were parameters investigated. The highest recovery efficiency of 83% was obtained for Scenedesmus obliquus at 1.5A, initial pH 9 and 6gL(-)(1) NaCl with power consumption of 3.84kWhkg(-)(1). Recovery efficiency of ECH process was comparable to literature reported centrifugation, filtration and chemical flocculation techniques but with a much lower power consumption. The ECH process with addition of electrolyte enhanced the lipid extraction by 22% without any adverse effects. The ECH process with non sacrificial carbon electrodes could be a possible harvesting step at commercial scale microalgal biomass production.

An ultra-low energy method for rapidly pre-concentrating microalgae

This study demonstrates that Nannochloropsis sp. can be effectively separated from its growth medium (0.2-0.3g/L) using electro-coagulation-flocculation in a 100mL batch reactor with nickel electrodes and a treatment time of only 4s. Minimum energy density input for effective separation is 0.03 kWh/m(3). Both energy input and treatment time are much smaller than reported elsewhere. The process results in rapid separation of microalgae (over 90% in 120 min) with minimal damage to algal cells (>90% still alive after processing). At around 4V input, algae can be effectively separated even in very low concentrations. Pulsing is equally effective in separating microalgae as continuous direct current of same magnitude and total exposure time. Algae can separate from their growth medium even if the suspension itself is not treated, but is mixed with treated saltwater with same conductivity. The described method has significant advantages including applicability to continuous processing and water reuse.

Reducing electrocoagulation harvesting costs for practical microalgal biodiesel production

Electrocoagulation has shown potential to be a primary microalgae harvesting technique for biodiesel production. However, methods to reduce energy and electrode costs are still necessary for practical application. Electrocoagulation tests were conducted on Nannochloris sp. and Dunaliella sp. using perforated aluminium and iron electrodes under various charge densities. Aluminium electrodes were shown to be more efficient than iron electrodes when harvesting both algal species. Despite the lower harvesting efficiency, however, the iron electrodes were more energy and cost efficient. Operational costs of less than $0.03/L oil were achieved when harvesting Nannochloris sp. with iron electrodes at 35% harvest efficiency, whereas aluminium electrodes cost $0.75/L oil with 42% harvesting efficiency. Increasing the harvesting efficiencies for both aluminium and iron electrodes also increased the overall cost per litre of oil, therefore lower harvesting efficiencies with lower energy inputs was recommended. Also, increasing the culturing salinity to 2 ppt sodium chloride for freshwater Nannochloris sp. was determined practical to improve the electrocoagulation energy efficiency despite a 25% reduction in cell growth.

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.

Continuous microalgae recovery using electrolysis: effect of different electrode pairs and timing of polarity exchange

Microalgae have great potential as a feedstock for biofuel production. Continuous operation is an important benefit of the continuous electrolytic microalgae (CEM) harvest system, but it is necessary to optimize cultivability and recovery efficiency in order to improve overall performance. Two pairs of best-candidate electrodes for polarity exchange (PE) were examined to improve these two key factors: (i) aluminum and dimensionally stable anode (Al-DSA), and (ii) Al-platinum (Al-Pt). Al-DSA was better than Al-Pt because it led to less cell damage and was less expensive. Moreover, cell viability and recovery were improved by optimizing the timing of PE. A P1:P2 ratio of 1:1.5 at 5min and 1:1.2 at 10min yielded the best results, with greatly reduced electricity consumption and enhanced cell viability and recovery. The CEM harvest system appears to be a well-suited option for the harvest of microalgae for biofuel production.