Bioprocess engineering principles of microalgal cultivation for sustainable biofuel production

Acclimated green microalgae consortium to treat sewage in an alternative urban WWTP in a coastal area of Central Italy

This study exposed a microalgal consortium formed by Auxenochlorella protothecoides, Tetradesmus obliquus, and Chlamydomonas reinhardtii to six mixed wastewater media containing different proportions of primary (P) or secondary (S) effluents diluted in centrate (C). Algae could grow at centrate concentrations up to 50 %, showing no significant differences between effluents. After acclimation, microalgae cultivated in 50%P-50%C and 50%S-50%C grew at a rate similar to that of control cultures (0.59-0.66 d-1). These results suggest that the consortium acclimated to both sewage streams by modulating the proportion of the species and their metabolism. Acclimation also altered the photosynthetic activity of wastewater-grown samples compared to the control, probably due to partial photoinhibition, changes in consortium composition, and changes in metabolic activity. No major differences were observed between the two streams with respect to biochemical composition, biomass yield, or bioremediation capacity of the cultivated algae but algae grown in the secondary effluent showed qualitatively higher exopolysaccharides (EPS) production than algae grown in primary. Regarding wastewater remediation, microalgae grown in both WW media showed proficient nutrient removal efficiencies (close to 100 %); however, the final pH value (close to 11) would be controversial if the system were upscaled as it is over the legal limit and would cause phosphorus precipitation, so that CO2 addition would be required. The theoretical scale-up of the microalgae system could achieve water treatment costs of 0.109 €·m-3, which was significantly lower than the costs of typical activated sludge systems.

Toward a modeling, optimization, and predictive control framework for fed-batch metabolic cybergenetics

Biotechnology offers many opportunities for the sustainable manufacturing of valuable products. The toolbox to optimize bioprocesses includes extracellular process elements such as the bioreactor design and mode of operation, medium formulation, culture conditions, feeding rates, and so on. However, these elements are frequently insufficient for achieving optimal process performance or precise product composition. One can use metabolic and genetic engineering methods for optimization at the intracellular level. Nevertheless, those are often of static nature, failing when applied to dynamic processes or if disturbances occur. Furthermore, many bioprocesses are optimized empirically and implemented with little-to-no feedback control to counteract disturbances. The concept of cybergenetics has opened new possibilities to optimize bioprocesses by enabling online modulation of the gene expression of metabolism-relevant proteins via external inputs (e.g., light intensity in optogenetics). Here, we fuse cybergenetics with model-based optimization and predictive control for optimizing dynamic bioprocesses. To do so, we propose to use dynamic constraint-based models that integrate the dynamics of metabolic reactions, resource allocation, and inducible gene expression. We formulate a model-based optimal control problem to find the optimal process inputs. Furthermore, we propose using model predictive control to address uncertainties via online feedback. We focus on fed-batch processes, where the substrate feeding rate is an additional optimization variable. As a simulation example, we show the optogenetic control of the ATPase enzyme complex for dynamic modulation of enforced ATP wasting to adjust product yield and productivity.

Are algae a promising ecofriendly approach to micro/nanoplastic remediation?

How to reduce microplastic pollution in aquatic ecosystem has become the focus of the global attention. The re-removal of microplastics of wastewater treatment plant (WWTP) effluent is gradually being put on the agenda. Recently, algae have been used as an ecofriendly remediation strategy for microplastic removal. Microplastics in sewage can be removed by algae through interception, capture, and entanglement, and can also form heterogeneous aggregates with algae, thereby reducing their free suspensions. Algae can recover nitrogen and carbon from wastewater and can be made into biochar, biofertilizers, and biofuels. However, problematically, this technology has been in the laboratory research stage, and existing research results cannot provide effective basis for its application. Microplastic removal via algae is influenced by wastewater flow rate, microplastic types, and pollutants. Microplastics are only physically fixed by algae, and ensuring that microplastics do not re-enter the environment during resource and capacity recovery is also a key factor limiting the implementation of this technology. The topic of this paper is to discuss the performance of the current tertiary wastewater treatment process - algae process to remove microplastics. Algae can remove nitrogen and phosphorus pollutants in sewage and remove microplastics at the same time, which can realize energy recovery and reduce ecological risks of the effluent. Although algae combined tertiary sewage treatment is a green technology for microplastic removal, its application still needs to be explored. The key challenges that need to be addressed, from single laboratory conditions to complex conditions, from small-scale testing to large-scale simulations, lie ahead of the application of this friendly technology.

Design and modelling of photobioreactor for the treatment of carpet and textile effluent using Diplosphaera mucosa VSPA

The current study investigated the potential of one less explored microalgae species, Diplosphaera mucosa VSPA, for treating carpet and textile effluent in a conventionally designed 10 L bubble column photobioreactor. To the best of our knowledge, this is the first study to evaluate COD (chemical oxygen demand) removal efficiency by microalgae in carpet effluent. To evaluate D. mucosa VSPA's potential, its growth and bioremediation efficacy were compared to those of a well-known strain, Chlorella pyrenoidosa. D. mucosa VSPA outperformed C. pyrenoidosa in both effluents, with the highest biomass concentration reaching 4.26 and 3.98 g/L in carpet and textile effluent, respectively. D. mucosa VSPA also remediated 94.0% of ammonium nitrogen, 71.6% of phosphate phosphorus, and 91.9% of chemical oxygen demand in carpet effluent, approximately 10% greater than that of C. pyrenoidosa. Both species also removed more than 65% of colour from both effluents, meeting the standard set by governing bodies. Microalgae growth and substrate removal patterns in the photobioreactor were simulated using photobiotreatment and the Gompertz model. Simulation results revealed that photobiotreatment was the better-fit model, concluded based on the coefficient of regression value and the second-order Akaike information criterion test. Modelling studies can assist in increasing the performance and scale-up of the photobioreactor.

Supplementary Information

The online version contains supplementary material available at 10.1007/s13205-023-03655-3.

Development of Microalgae Biodiesel: Current Status and Perspectives

Microalgae are regarded as a promising source of biodiesel. In contrast with conventional crops currently used to produce commercial biodiesel, microalgae can be cultivated on non-arable land, besides having a higher growth rate and productivity. However, microalgal biodiesel is not yet regarded as economically competitive, compared to fossil fuels and crop-based biodiesel; therefore, it is not commercially produced. This review provides an overall perspective on technologies with the potential to increase efficiency and reduce the general costs of biodiesel production from microalgae. Opportunities and challenges for large-scale production are discussed. We present the current scenario of Brazilian research in the field and show a successful case in the research and development of microalgal biodiesel in open ponds by Petrobras. This publicly held Brazilian corporation has been investing in research in this sector for over a decade.

Integrated electrocoagulation-flotation of microalgae to produce Mg-laden microalgal biochar for seeding struvite crystallization

Developing sustainable materials for recovering and recycling nutrients from wastewater is critically needed for nutrients such as phosphorus that have a diminishing supply. Struvite crystallization is emerging as a promising strategy for phosphorus recovery which can be enhanced with seeding through microalgal biochar. The main bottleneck of using microalgae is its high harvesting cost. In this study, an integrated electrocoagulation-flotation (ECF) process is used to recover and at the same time modify the algal surface with magnesium anode and inert carbon cathode. Harvesting efficiency of 98% was achieved with 40.78 mA cm⁻², 0.5 cm inter-electrode distance and energy consumption of 4.03 kWh kg⁻¹ in 15 min. The harvested microalgae were pyrolyzed to obtain a yield of 52.90% Mg-laden microalgal biochar. Simultaneously, surface impregnation of 28% magnesium was attained as confirmed by Scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS). Phosphorus recovery and struvite yield of 93.70% and 2.66 g L⁻¹, respectively, were obtained from dosing 1.50 g L⁻¹ Mg-laden microalgal biochar. Comparison of physicochemical characteristics of residual supernatant after microalgal harvesting and struvite recovery showed that the combined use of both the residuals can serve as a sustainable growth medium for microalgae. The overall operating cost of the integrated process was found to be 2.48 USD kg⁻¹ with a total energy consumption of 10.76 kWh kg⁻¹, which was found to be lower than conventional harvesting unit processes such as centrifugation and filtration. This novel approach can help attaining a circular bioeconomy by encompassing nutrient recovery and waste management in an integrated process.

Research trends and market opportunities of microalgal biorefinery technologies from circular bioeconomy perspectives

Microalgae as an alternative feedstock for sustainable bio-products have gained significant interest over years. Even though scientific productivity related to microalgae-based research has increased in recent decades, translation to industrial scale is still lacking. Therefore, it is essential to understand the current state-of-art and, identify research gaps and hotspots driving industrial scale up. The present review through scientometric analysis attempted to delineate the research evolution contributing to this emerging field. The research trends were analysed over the last decade globally highlighting the collaborative network between the countries. The comprehensive knowledge map generated confirmed microalgal biorefinery as a scientifically active field, where the present research interest is focussed on synergistically integrating the unit processes involved to make it enviro-economically feasible. Market opportunities and regulatory policy requirements along with the consensus need to adopt circular bio-economy perspectives were highlighted to facilitate real-time implementation of microalgal biorefinery.

Effective Prediction of Monthly Heat Transfer Characteristics in a Thin-Layer Cascade Reactor Subjected to Outdoor Conditions

Algal biofuels are intriguingly a renewable energy source that could partially substitute fossil fuels, but further research is required to optimise the growth parameters and establish competitive large-scale cultivation systems. Algal growth is directly dependent on momentum, heat, and mass transfer within the photobioreactor and environmental conditions. Therefore, in this computational study, the heat transfer between the thin-layer cascade (TLC) reactor and its surrounding was reported based on static (location and reactor geometry) and dynamic (air temperature, solar irradiance, and wind velocity) parameters. The resulting model was validated using experimental data. The Nusselt number and the monthly average water temperature were computed to investigate the heat transfer phenomena between the TLC reactor and atmosphere. In addition, a novel corelation was used to estimate the evaporative losses from the TLC reactor. The effect of geometric properties (inclination angle of the reactor, water depth, and channel width) was evaluated on heat transfer. Results showed that heat transfer rate and the optimum water temperature for algal growth were significantly affected by hydrodynamics, environmental conditions, and reactor design. Water temperature decreased with the increase in channel width, water depth, and slope angle of the reactor. Furthermore, algal productivity declined with the increase in the amount of evaporated water.

Cultivation of two Chlorella species in Open sewage contaminated channel wastewater for biomass and biochemical profiles: Comparative lab-scale approach

Open sewage contaminated channel wastewater (OSCCW) has high pollutant loads, responsible for eutrophication, when mixed with various channels of urban communities. But, these pollutants can be converted and recovered into useful end products with the help of algal species. In this study, two species of Chlorella (C. vulgaris and C. pyrenoidosa) were selected and investigated for the production of algal biomass and nutrient removal efficiencies with 50% concentration of OSCCW, in a comparative way at lab-scale. Chlorella sp. cultivated in OSCCW have removed nitrate (76.9-78.8%) and phosphate (67.6-79.7%) whereas COD (72.4-76.2%) and BOD (62.3-72.4%) respectively. Correlation analysis was investigated between physico-chemical parameters and biochemical profile of both species to analyze the positive and negative correlation between two variables. The bio-chemical profile and biomass productivity of both species of Chlorella were observed well on the basis of productivity of biomass (60.1, 56.5 mg/l/d), carbohydrate (15.71, 8.82 mg/l/d), protein (11.21, 15.82 mg/l/d), lipid (20.8, 17.5 mg/l/d) and chlorophyll (0.78, 0.67 mg/l/d) in OSCCW. The maximum lipid content (34.6%) was obtained with C. pyrenoidosa as compared to C. vulgaris. Findings also support that OSCCW is well-off with nutrient resources, which can be suitable alternative for algal biomass production and remediated wastewater can be used for animal and fish farming type activities.

Integrated microalgal biorefinery for the production and application of biostimulants in circular bioeconomy

Adverse detrimental impacts of environmental pollution over the health regimen of people has driven a shift in lifestyle towards cleaner and natural resources, especially in the aspects of food production and consumption. Microalgae are considered a rich source of high value metabolites to be utilized as plant growth biostimulants. These organisms however, are underrated compared to other microbial counterparts, due to inappropriate knowledge on the technical, enviro-economical constrains leading to low market credibility. Thus, to avert these issues, the present review comprehensively discusses the biostimulatory potential of microalgae interactively combined with circular bio-economy perspectives. The biochemical content and intracellular action mechanism of microalgal biostimulants were described. Furthermore, detailed country-wise market trends along with the description of the existing regulatory policies are included. Enviro-techno-economic challenges are discussed, and the consensus need for shift to biorefinery and circular bio-economy concept are emphasized to achieve sustainable impacts during the commercialization of microalgal biostimulants.

Insights into the potential impact of algae-mediated wastewater beneficiation for the circular bioeconomy: A global perspective

Algae-based technologies are one of the emerging solutions to societal issues such as accessibility to clean water and carbon-neutral energy and are a contender for the circular bioeconomy. In this review, recent developments in the use of different algal species for nutrient recovery and biomass production in wastewater, challenges, and future perspectives have been addressed. The ratio and bioavailability of nutrients in wastewater are vital parameters, which significantly impact nutrient recovery efficiency and algal biomass production. However, the optimum nutrient concentration and ratio may vary depending upon the microalgal species as well as cultivation conditions. The use of indigenous algae and algae-based consortia with other microorganisms has been proved promising in improving nutrient recovery efficiency and biomass production in pilot scale operations. However, environmental and cultivation conditions also play a significant role in determining the feasibility of the process. This review further focused on the assessment of the potential benefits of algal biomass production, renewable biofuel generation, and CO₂ sequestration using wastewater in different countries on the basis of available data on wastewater generation and estimated nutrient contents. It was estimated that 5-10% replacement of fossil crude requirement with algal biofuels would require ~952-1903 billion m³ of water, 10-21 billion tons of nitrogen, and 2-4 billion tons of phosphorus fertilizers. In this context, coupling wastewater treatment and algal biomass production seem to be the most sustainable option with potential global benefits of polishing wastewater through nutrients recycling and carbon dioxide sequestration.

Anaerobic digestion and agronomic applications of microalgae for its sustainable valorization

Microalgae are considered potential candidates in biorefinery processes, and due to their biochemical properties, they can be used in the production of biofuels such as biogas, as well as for bioremediation of liquid effluents. The objective of this review is to study the current status of microalgae anaerobic digestion and agricultural uses (as bio-stimulants and biofertilizers), starting from microalgae cultivation. Indeed, the efficiency of these processes necessarily depends on the evaluation of different biotic and abiotic factors that affect the growth of microalgae. However, the adaptation and the optimization of process parameters on a large scale is also limited by energy and economic constraints. Moreover, the integration of biogas production processes with microalgae cultivation allows a nutrients and CO2 virtuous loop, thus promoting the sustainability of the process. Finally, this paper provides a general overview of biogas and biofertilizers production combination, as well as the related challenges and recommended future research perspectives to complement the gap in the literature.

Integrated Approach for Wastewater Treatment and Biofuel Production in Microalgae Biorefineries

The increasing world population generates huge amounts of wastewater as well as large energy demand. Additionally, fossil fuel’s combustion for energy production causes the emission of greenhouse gases (GHG) and other pollutants. Therefore, there is a strong need to find alternative green approaches for wastewater treatment and energy production. Microalgae biorefineries could represent an effective strategy to mitigate the above problems. Microalgae biorefineries are a sustainable alternative to conventional wastewater treatment processes, as they potentially allow wastewater to be treated at lower costs and with lower energy consumption. Furthermore, they provide an effective means to recover valuable compounds for biofuel production or other applications. This review focuses on the current scenario and future prospects of microalgae biorefineries aimed at combining wastewater treatment with biofuel production. First, the different microalgal cultivation systems are examined, and their main characteristics and limitations are discussed. Then, the technologies available for converting the biomass produced during wastewater treatment into biofuel are critically analyzed. Finally, current challenges and research directions for biofuel production and wastewater treatment through this approach are outlined.

Phaeodactylum tricornutum cultivation under mixotrophic conditions with glycerol supplied with ultrafiltered digestate: A simple biorefinery approach recovering C and N

Phaeodactylum tricornutum was cultivated mixotrophically in batch mode providing glycerol as the C source, i.e., 0.02, 0.03 and 0.04 Mol L^-1 glycerol, and ultrafiltered digestate (UF) as an N source. Biomass productivity, biomass composition, N efficiency use and total energy balance were recorded and compared to those under autotrophic conditions. Under mixotrophic conditions (0.03 Mol L^-1 and 0.04 Mol L^-1 glycerol), biomass productivity of P. tricornutum increased by 1.29 and 1.60 times in comparison with autotrophic conditions. Algal protein content declined as glycerol concentration increased, contrary to the case of the carbohydrate content. Lipid content did not change but unexpectedly, a lower unsaturated fatty acid in mixotrophic culture was observed than that from autotrophic culture. Mixotrophic conditions offered a higher energy recovery efficiency (EF_t) than autotrophic conditions (5.7 % in 0.04 Mol L^-1 glycerol and 4.2 % in autotrophic trial, respectively). Additionally, the efficiency of glycerol conversion into biomass (EF_gly) increased with the glycerol dose, achieving 22.8 % for 0.04 Mol L^-1 glycerol.

Algal biodiesel production with engineered biochar as a heterogeneous solid acid catalyst

This study evaluates the use of engineered biochar as a heterogeneous solid acid catalyst for transesterification of algal oil derived from a native microalgal consortium. Biochar derived from sugarcane bagasse, coconut shell, corncob and peanut shell were evaluated for catalytic activity following surface modification. Peanut shell pyrolyzed at 400 °C with the sulfonic acid density of 0.837 mmol/g having 6.616 m²/g surface area was selected for efficient catalysis. The efficiency of transesterification was evaluated with 1-7 wt% catalyst loading, methanol: oil ratio of 6:1 to 30:1 at 55-85 °C over 2-8 h. Biodiesel yield of 94.91% was obtained with 5 wt% catalyst loading, MeOH: oil ratio of 20:1 at 65 °C after 4 h. Spectral analysis of algal biodiesel showed the presence of functional groups corresponding to esters. GC-MS analysis revealed the prominent presence of palmitic and oleic acids, further advocating the suitability of the technology for commercial application.

Biological nutrient recovery from human urine by enriching mixed microalgal consortium for biodiesel production

Utilization of waste resources is necessary to harness the long-term sustainability of algal technology. The study focused on the use of human urine as the basic nutrient source for culturing native microalgal consortium and further optimized the process parameters using response surface methodology. A full factorial, central composite rotatable design (CCRD) with three variables: urine concentration (1-10% vol of urine/vol of distil water [%v/v]), pH (6.5-9) and light intensity (50-350 μmolphotonsm^-2sec^-1) was used to evaluate the microalgal biomass and lipid content. Results indicated that at 95% confidence limits, the selected factors influence the biomass and lipid productivity. The maximum biomass productivity of 211.63 ± 1.40 mg l^-1 d^-1 was obtained under optimized conditions with 6.50% v/v of urine, pH of 7.69 and at light intensity of 205.40 μmolphotonsm^-2sec^-1. The lipid content was found to increase from 18.96 ± 1.30% in control media to 26.27 ± 1.94% under optimal conditions. The interactive effect of variables over the microalgal biomass and lipid content has also been elucidated. The data obtained were comparable to the BG11 media (control). Optimized diluted urine media in the presence of ammonium ions and under limited nitrate showed better lipid yields. Significant lipid biomolecules were detected in the algal oil extracts obtained from the diluted urine media characterized by Fourier transform infrared spectroscopy (FTIR) and Nuclear magnetic resonance (NMR). Gas chromatography-mass spectrometry (GCMS) revealed the presence of several monounsaturated and polyunsaturated fatty acids in the transesterified algal oil. Such studies would aid in technically realizing the field scale cultivation of microalgae for biofuels.

Grid columnar flat panel photobioreactor with immobilized photosynthetic bacteria for continuous photofermentative hydrogen production

A biophotoreactor with a transparent glass flat panel with polymethyl methacrylate (PMMA) grid columnar for enhanced biofilm growth with Rhodopseudomonas palustris GCA009 was developed and tested at 590 nm incident light. Continuous photofermentative hydrogen production from glucose was tested using this novel reactor. At light intensity of 210 W/m², feed substrate concentration of 56.0 mmol/L, and crossflow velocity of 1.68 × 10^-6 m/s, a maximum hydrogen production rate of 32.6 mmol/L-d (3.56 mmol/m²-h), hydrogen yield of 1.15 mol H₂/mol glucose and light conversion efficiency of 5.34% can be achieved. Since the revised grid columnar effectively enlarged the surface area of reactor and enhanced cell attachment, the present reactor design led to higher hydrogen production rates than literature works.