Development of a novel multi-column airlift photobioreactor with easy scalability by means of computational fluid dynamics simulations and experiments

Hydrodynamics and mass transfer of concentric-tube internal loop airlift reactors: A review

The concentric-tube internal loop airlift reactor is a typical reactor configuration which has been adopted for a myriad of chemical and biological processes. The reactor hydrodynamics (including mixing) and the mass transfer between the gas and liquid phases remarkably affect the operational conditions and thus are crucial to the overall reactor performance. Hence, this study aims at providing a thorough description of the basic concepts and a comprehensive review of the relevant reported studies on the hydrodynamics and mass transfer of the concentric-tube internal loop airlift reactors, taking microalgae cultivation as an exemplary application. In particular, the reactor characteristics, geometry, CFD modeling, experimental characterization, and scale up considerations are elucidated. The research gaps for future research and development are also identified.

A Thermosiphon Photobioreactor for Photofermentative Hydrogen Production by Rhodopseudomonas palustris

A thermosiphon photobioreactor (TPBR) can potentially be used for biohydrogen production, circumventing the requirement for external mixing energy inputs. In this study, a TPBR is evaluated for photofermentative hydrogen production by Rhodopseudomonas palustris (R. palustris). Experiments were conducted in a TPBR, and response surface methodology (RSM), varying biomass concentration, and light intensity and temperature were employed to determine the operating conditions for the enhancement of both hydrogen production as well as biomass suspension. Biomass concentration was found to have had the most pronounced effect on both hydrogen production as well as biomass suspension. RSM models predicted maximum specific hydrogen production rates of 0.17 mol m⁻³h⁻¹ and 0.21 mmol g_CDW⁻¹h⁻¹ at R. palustris concentrations of 1.21 and 0.4 g L⁻¹, respectively. The experimentally measured hydrogen yield was in the range of 45 to 77% (±3.8%), and the glycerol consumption was 8 to 19% (±0.48). At a biomass concentration of 0.40 g L⁻¹, the highest percentage of biomass (72.3%), was predicted to remain in suspension in the TPBR. Collectively, the proposed novel photobioreactor was shown to produce hydrogen as well as passively circulate biomass.

Multifaceted strategies for economic production of microalgae Haematococcus pluvialis-derived astaxanthin via direct conversion of CO2

Owing to its strong antioxidant properties, astaxanthin has a high market price in the nutraceutical and pharmaceutical fields, and its demand is increasing. Furthermore, with an increase in the demand for green technology, astaxanthin production through direct CO₂ conversion using the autotrophic green microalga Haematococcus pluvialis as a bio-platform has received much attention. Large-scale outdoor cultivation of H. pluvialis using waste CO₂ sources and sunlight can secure sustainability and improve economic efficiency. However, low strain performance, reduced light utilization because of increased cell density, and inefficient transfer of gaseous CO₂ into liquid culture broth hinder its large-scale commercialization of astaxanthin. Herein, we presented a multifaceted strategy, including the development of high-efficiency strains, a culture system for astaxanthin accumulation, and astaxanthin extraction from biomass, for economically producing astaxanthin from H. pluvialis through direct CO₂ conversion. Future perspectives were presented by comparing and analyzing various previous studies conducted using the latest technology.

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.

A Review of Energy Consumption in the Acquisition of Bio-Feedstock for Microalgae Biofuel Production

Microalgae biofuel is expected to be an ideal alternative to fossil fuels to mitigate the effects of climate change and the energy crisis. However, the production process of microalgae biofuel is sometimes considered to be energy intensive and uneconomical, which limits its large-scale production. Several cultivation systems are used to acquire feedstock for microalgal biofuels production. The energy consumption of different cultivation systems is different, and the concentration of culture medium (microalgae cells contained in the unit volume of medium) and other properties of microalgae vary with the culture methods, which affects the energy consumption of subsequent processes. This review compared the energy consumption of different cultivation systems, including the open pond system, four types of closed photobioreactor (PBR) systems, and the hybrid cultivation system, and the energy consumption of the subsequent harvesting process. The biomass concentration and areal biomass production of every cultivation system were also analyzed. The results show that the flat-panel PBRs and the column PBRs are both preferred for large-scale biofuel production for high biomass productivity.

Synergising biomass growth kinetics and transport mechanisms to simulate light/dark cycle effects on photo-production systems

Light attenuation is a primary challenge limiting the upscaling of photobioreactors for sustainable bio-production. One key to this challenge, is to model and optimise the light/dark cycles so that cells within the dark region can be frequently transferred to the light region for photosynthesis. Therefore, this study proposes the first mechanistic model to integrate the light/dark cycle effects into biomass growth kinetics. This model was initially constructed through theoretical derivation based on the intracellular reaction kinetics, and was subsequently modified by embedding a new parameter, effective light coefficient, to account for the effects of culture mixing. To generate in silico process data, a new multiscale reactive transport modelling strategy was developed to couple fluid dynamics with biomass growth kinetics and light transmission. By comparing against previous experimental and computational studies, the multiscale model shows to be of high accuracy. Based on its simulation result, an original correlation was proposed to link effective light coefficient with photobioreactor gas inflow rate; this has not been done before. The impact of this study is that by using the proposed mechanistic model and correlation, we can easily control and optimise photobioreactor gas inflow rates to alleviate light attenuation and maintain a high biomass growth rate.

Perspective Design of Algae Photobioreactor for Greenhouses—A Comparative Study

The continued growth and evolving lifestyles of the human population require the urgent development of sustainable production in all its aspects. Microalgae have the potential of the sustainable production of various commodities; however, the energetic requirements of algae cultivation still largely contribute to the overall negative balance of many operation plants. Here, we evaluate energetic efficiency of biomass and lipids production by Chlorella pyrenoidosa in multi-tubular, helical-tubular, and flat-panel airlift pilot scale photobioreactors, placed in an indoor environment of greenhouse laboratory in Central Europe. Our results show that the main energy consumption was related to the maintenance of constant light intensity in the flat-panel photobioreactor and the culture circulation in the helical-tubular photobioreactor. The specific power input ranged between 0.79 W L−1 in the multi-tubular photobioreactor and 6.8 W L−1 in the flat-panel photobioreactor. The construction of multi-tubular photobioreactor allowed for the lowest energy requirements but also predetermined the highest temperature sensitivity and led to a significant reduction of Chlorella productivity in extraordinary warm summers 2018 and 2019. To meet the requirements of sustainable yearlong microalgal production in the context of global change, further development towards hybrid microalgal cultivation systems, combining the advantages of open and closed systems, can be expected.

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.

A critical review on designs and applications of microalgae-based photobioreactors for pollutants treatment

The development of the photobioreactors (PBs) is recently noticeable as cutting-edge technology while the correlation of PBs' engineered elements such as modellings, configurations, biomass yields, operating conditions and pollutants removal efficiency still remains complex and unclear. A systematic understanding of PBs is therefore essential. This critical review study is to: (1) describe the modelling approaches and differentiate the outcomes; (2) review and update the novel technical issues of PBs' types; (3) study microalgae growth and control determined by PBs types with comparison made; (4) progress and compare the efficiencies of contaminants removal given by PBs' types and (5) identify the future perspectives of PBs. It is found that Monod model's shortcoming in internal substrate utilization is well fixed by modified Droop model. The corroborated data also remarks an array of PBs' types consisting of flat plate, column, tubular, soft-frame and hybrid configuration in which soft-frame and hybrid are the latest versions with higher flexibility, performance and smaller foot-print. Flat plate PBs is observed with biomass yield being 5 to 20 times higher than other PBs types while soft-frame and membrane PBs can also remove pharmaceutical and personal care products (PPCPs) up to 100%. Looking at an opportunity for PBs in sustainable development, the flat plate PBs are applicable in PB-based architectures and infrastructures indicating an encouraging revenue-raising potential.

Same but different-Scale up and numbering up in electrobiotechnology and photobiotechnology

Facing energy problems, there is a strong demand for new technologies dealing with the replacement of fossil fuels. The emerging fields of biotechnology, photobiotechnology and electrobiotechnology, offer solutions for the production of fuels, energy, or chemicals using renewable energy sources (light or electrical current e.g. produced by wind or solar power) or organic (waste) substrates. From an engineering point of view both technologies have analogies and some similar challenges, since both light and electron transfer are primarily surface-dependent. In contrast to that, bioproduction processes are typically volume dependent. To allow large scale and industrially relevant applications of photobiotechnology and electrobiotechnology, this opinion first gives an overview over the current scales reached in these areas. We then try to point out the challenges and possible methods for the scale up or numbering up of the reactors used. It is shown that the field of photobiotechnology is by now much more advanced than electrobiotechnology and has achieved industrial applications in some cases. We argue that transferring knowledge from photobiotechnology to electrobiotechnology can speed up the development of the emerging field of electrobiotechnology. We believe that a combination of scale up and numbering up, as it has been shown for several photobiotechnological reactors, may well lead to industrially relevant scales in electrobiotechnological processes allowing an industrial application of the technology in near future.