The Microalgae Biorefinery: A Perspective on the Current Status and Future Opportunities Using Genetic Modification

Microplate-Based Cell Viability Assay as a Cost-Effective Alternative to Flow Cytometry for Microalgae Analysis

Cell viability is a critical indicator for assessing culture quality in microalgae cultivation for biorefinery and bioremediation. Fluorescent dyes that distinguish viable from nonviable cells can enable viability quantification based on the percentage of live cells. However, fluorescence analysis using the typical flow cytometry method is costly and impractical for industrial applications. To address this, we developed new microplate assays utilizing fluorescein diacetate as a live cell stain and erythrosine B as a dead cell stain. These assays provide a low-cost, simple, and reliable method of assessing cell viability. The proposed microplate assays were successfully applied to monitor the viability of the microalgae Dunaliella viridis under carbon and nitrogen limitation stresses and demonstrated good agreement with flow cytometry measurements. We conducted a systematic investigation of the effects of dye concentration, incubation time, and background fluorescence on the microplate assays' performance. Further, we provide a comprehensive review of commonly used fluorescent dyes for microalgae staining, discuss strategies to enhance assay performance, and offer recommendations for dye selection and protocol development. This study presents a comprehensive new method for microplate-based viability analysis, providing valuable insights for future microalgae viability assessments and applications.

Metabolic engineering and synthetic biology strategies for producing high-value natural pigments in Microalgae

Microalgae are microorganisms capable of producing bioactive compounds using photosynthesis. Microalgae contain a variety of high value-added natural pigments such as carotenoids, phycobilins, and chlorophylls. These pigments play an important role in many areas such as food, pharmaceuticals, and cosmetics. Natural pigments have a health value that is unmatched by synthetic pigments. However, the current commercial production of natural pigments from microalgae is not able to meet the growing market demand. The use of metabolic engineering and synthetic biological strategies to improve the production performance of microalgal cell factories is essential to promote the large-scale production of high-value pigments from microalgae. This paper reviews the health and economic values, the applications, and the synthesis pathways of microalgal pigments. Overall, this review aims to highlight the latest research progress in metabolic engineering and synthetic biology in constructing engineered strains of microalgae with high-value pigments and the application of CRISPR technology and multi-omics in this context. Finally, we conclude with a discussion on the bottlenecks and challenges of microalgal pigment production and their future development prospects.

Exploiting AGPase genes and encoded proteins to prioritize development of optimum engineered strains in microalgae towards sustainable biofuel production

Although ADP glucose pyrophosphorylase (AGPase), with two large subunits (ls) and two small subunits (ss), is a promising knockout target for increasing the neutral lipid content, the details regarding the sequence-structure features and their distribution within metabolic system in microalgae is rather limited. Against this backdrop, a comprehensive genome-wide comparative analysis on 14 sequenced microalgal genomes was performed. For the first time the heterotetrameric structure of the enzyme and the interaction of the catalytic unit with the substrate was also studied. Novel findings of the present study includes: (i) at the DNA level, the genes controlling the ss are more conserved than those controlling the ls; the variation in both the gene groups is mainly due to exon number, exon length and exon phase distribution; (ii) at protein level, the ss genes are more conserved relative to those for ls; (III) three putative key consensus sequences 'LGGGAGTRLYPLTKNRAKPAV', 'WFQGTADAV' and 'ASMGIYVFRKD' were ubiquitously conserved in all the AGPases; (iv) molecular dynamics investigations revealed that the modeled AGPase heterotetrameric structure, from oleaginous algae Chlamydomonas reinharditii, was completely stable in real time environment; (v) The binding interfaces of catalytic unit, ssAGPase, from C. reinharditii with α-D-glucose 1-phosphate (αGP) was also analyzed. The results of the present study have provided system-based insights into the structure-function of the genes and encoded proteins, which provided clues for exploitation of variability in these genes that, could be further utilized to design site-specific mutagenic experiments for engineering of microalgal strains towards sustainable development of biofuel.

Mass Cultivation of Microalgae: II. A Large Species Pulsing Blue Light Concept

If mass cultivation of photoautotrophic microalgae is to gain momentum and find its place in the new "green future", exceptional optimizations to reduce production costs must be implemented. Issues related to illumination should therefore constitute the main focus, since it is the availability of photons in time and space that drives synthesis of biomass. Further, artificial illumination (e.g., LEDs) is needed to transport enough photons into dense algae cultures contained in large photobioreactors. In the present research project, we employed short-term O₂ production and 7-day batch cultivation experiments to evaluate the potential to reduce illumination light energy by applying blue flashing light to cultures of large and small diatoms. Our results show that large diatom cells allow more light penetration for growth compared to smaller cells. PAR (400-700 nm) scans yielded twice as much biovolume-specific absorbance for small biovolume (avg. 7070 μm³) than for large biovolume (avg. 18,703 μm³) cells. The dry weight (DW) to biovolume ratio was 17% lower for large than small cells, resulting in a DW specific absorbance that was 1.75 times higher for small cells compared to large cells. Blue 100 Hz square flashing light yielded the same biovolume production as blue linear light in both the O₂ production and batch experiments at the same maximum light intensities. We therefore suggest that, in the future, more focus should be placed on researching optical issues in photobioreactors, and that cell size and flashing blue light should be central in this.

A review on the sustainable procurement of microalgal biomass from wastewaters for the production of biofuels

The feasibility of microalgal biomass as one of the most promising and renewable sources for the production of biofuels is being studied extensively. Microalgal biomass can be cultivated under photoautotrophic, heterotrophic, photoheterotrophic, and mixotrophic cultivation conditions. Photoautotrophic cultivation is the most common way of microalgal biomass production. Under mixotrophic cultivation, microalgae can utilize both organic carbon and CO2 simultaneously. Mixotrophic cultivation depicts higher biomass productivity as compared to photoautotrophic cultivation. It is evident from the literature that mixotrophic cultivation yields higher quantities of polyunsaturated fatty acids as compared to that photoautotrophic cultivation. In this context, for economical biomass production, the organic carbon of industrial wastewaters can be valorized for the mixotrophic cultivation of microalgae. Following the way, contaminants' load of wastewaters can be reduced while concomitantly producing highly productive microalgal biomass. This review focuses on different aspects covering the sustainable cultivation of different microalgal species in different types of wastewaters.

A review on the current status and post-pandemic prospects of third-generation biofuels

The rapid increase in fossil fuel depletion, environmental degradations, and industrialization have encouraged the need and production of sustainable fuel alternatives. This has led to the increase in interest in biofuels, especially third-generation biofuels produced from microalgae since they do not compete with food and land supplies. However, the global share for these biofuels has been inadequate recently, especially due to the ongoing global pandemic. Therefore, this paper offers a review of the state-of-the-art study of the production field of third-generation biofuel from microalgae. The current review aims to focus on the different aspects of algal biofuel production that requires further attention to produce it at a large scale. It was found that several strategies during the life cycle of algal biofuel production can significantly increase its quality and yield while reducing cost, energy, and other related attributes. This paper also focuses on the challenges for large-scale production of third-generation biofuels pre and post COVID-19 to better understand the barriers. The high cost of this fuel’s production and sale tends to be the major reason behind the lack of large-scale production, hence, inadequacy to meet the global need. Third-generation biofuel has so much to offer including many integrated applications and advanced uses in the future fuel industry. Therefore, it is important to cope with the ongoing circumstances and emphasize the future of algal biofuel as a sustainable source.

Carotenoid Production from Microalgae: The Portuguese Scenario

Microalgae have an outstanding capacity to efficiently produce value-added compounds. They have been inspiring researchers worldwide to develop a blue biorefinery, supporting the development of the bioeconomy, tackling the environmental crisis, and mitigating the depletion of natural resources. In this review, the characteristics of the carotenoids produced by microalgae are presented and the downstream processes developed to recover and purify them are analyzed, considering their main applications. The ongoing activities and initiatives taking place in Portugal regarding not only research, but also industrialization under the blue biorefinery concept are also discussed. The situation reported here shows that new techniques must be developed to make microalgae production more competitive. Downstream pigment purification technologies must be developed as they may have a considerable impact on the economic viability of the process. Government incentives are needed to encourage a constructive interaction between academics and businesses in order to develop a biorefinery that focuses on high-grade chemicals.

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

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

Photoautotrophic and Mixotrophic Cultivation of Polyhydroxyalkanoate-Accumulating Microalgae Consortia Selected under Nitrogen and Phosphate Limitation

Microalgae consortia were photoautotrophically cultivated in sequencing batch photobioreactors (SBPRs) with an alteration of the normal growth and starvation (nutrient limitation) phases to select consortia capable of polyhydroxyalkanoate (PHA) accumulation. At the steady state of SBPR operation, the obtained microalgae consortia, selected under nitrogen and phosphate limitation, accumulated up to 11.38% and 10.24% of PHA in their biomass, which was identified as poly(3-hydroxybutyrate) (P3HB). Photoautotrophic and mixotrophic batch cultivation of the selected microalgae consortia was conducted to investigate the potential of biomass and PHA production. Sugar source supplementation enhanced the biomass and PHA production, with the highest PHA contents of 10.94 and 6.2%, and cumulative PHA productions of 100 and 130 mg/L, with this being achieved with sugarcane juice under nitrogen and phosphate limitation, respectively. The analysis of other macromolecules during batch cultivation indicated a high content of carbohydrates and lipids under nitrogen limitation, while higher protein contents were detected under phosphate limitation. These results recommended the selected microalgae consortia as potential tools for PHA and bioresource production. The mixed-culture non-sterile cultivation system developed in this study provides valuable information for large-scale microalgal PHA production process development following the biorefinery concept.

How does the Internet of Things (IoT) help in microalgae biorefinery?

Microalgae biorefinery is a platform for the conversion of microalgal biomass into a variety of value-added products, such as biofuels, bio-based chemicals, biomaterials, and bioactive substances. Commercialization and industrialization of microalgae biorefinery heavily rely on the capability and efficiency of large-scale cultivation of microalgae. Thus, there is an urgent need for novel technologies that can be used to monitor, automatically control, and precisely predict microalgae production. In light of this, innovative applications of the Internet of things (IoT) technologies in microalgae biorefinery have attracted tremendous research efforts. IoT has potential applications in a microalgae biorefinery for the automatic control of microalgae cultivation, monitoring and manipulation of microalgal cultivation parameters, optimization of microalgae productivity, identification of toxic algae species, screening of target microalgae species, classification of microalgae species, and viability detection of microalgal cells. In this critical review, cutting-edge IoT technologies that could be adopted to microalgae biorefinery in the upstream and downstream processing are described comprehensively. The current advances of the integration of IoT with microalgae biorefinery are presented. What this review discussed includes automation, sensors, lab-on-chip, and machine learning, which are the main constituent elements and advanced technologies of IoT. Specifically, future research directions are discussed with special emphasis on the development of sensors, the application of microfluidic technology, robotized microalgae, high-throughput platforms, deep learning, and other innovative techniques. This review could contribute greatly to the novelty and relevance in the field of IoT-based microalgae biorefinery to develop smarter, safer, cleaner, greener, and economically efficient techniques for exhaustive energy recovery during the biorefinery process.

Production of Microalgal Biomass in Photobioreactors as Feedstock for Bioenergy and Other Uses: A Techno-Economic Study of Harvesting Stage

The cultivation of microalgae has become a viable option to mitigate increase in CO2 in the atmosphere generated by industrial activities since they can capture CO2 as a carbon source for growth. Besides, they produce significant amounts of oils, carbohydrates, proteins, and other compounds of economic interest. There are several investigations related to the process, however, there is still no optimal scenario, since may depend on the final use of the biomass. The objective of this work was to develop a techno-economic evaluation of various technologies in harvesting and drying stages. The techno-economic estimation of these technologies provides a variety of production scenarios. Photobioreactors were used considering 1 ha as a cultivation area and a biomass production of 22.66 g/m2/day and a CO2 capture of 148.4 tons/ha/year was estimated. The production scenarios considered in this study have high energy demand and high operating costs (12.09–12.51 kWh/kg and US $210.05–214.59/kg). These results are mainly a consequence of the use of tubular photobioreactors as a biomass culture system. However, the use of photobioreactors in the production of microalgal biomass allows it to be obtained in optimal conditions for its use in the food or pharmaceutical industry.

Review on integrated biofuel production from microalgal biomass through the outset of transesterification route: a cascade approach for sustainable bioenergy

In recent years, microalgal feedstocks have gained immense potential for sustainable biofuel production. Thermochemical, biochemical conversions and transesterification processes are employed for biofuel production. Especially, the transesterification process of lipid molecules to fatty acid alkyl esters (FAAE) is being widely employed for biodiesel production. In the case of the extractive transesterification process, biodiesel is produced from the extracted microalgal oil. Whereas In-situ (reactive) transesterification allows the direct conversion of microalgae to biodiesel avoiding the sequential steps, which subsequently reduces the production cost. Though microalgae have the highest potential to be an alternate renewable feedstock, the minimization of biofuel production cost is still a challenge. The biorefinery approaches that rely on simple cascade processes involving cost-effective technologies are the need of an hour for sustainable bioenergy production using microalgae. At the same time, combining the biorefineries for both (i) high value-low volume (food and health supplements) and (ii) low value- high volume (waste remediation, bioenergy) from microalgae involves regulatory and technical problems. Waste-remediation and algal biorefinery were extensively reviewed in many previous reports. On the other hand, this review focuses on the cascade processes for efficient utilization of microalgae for integrated bioenergy production through the transesterification. Microalgal biomass remnants after the transesterification process, comprising carbohydrates as a major component (process flow A) or the carbohydrate fraction after bio-separation of pretreated microalgae (process flow B) can be utilized for bioethanol production. Therefore, this review concentrates on the cascade flow of integrated bioprocessing methods for biodiesel and bioethanol production through the transesterification and biochemical routes. The review also sheds light on the recent combinatorial approaches of transesterification of microalgae. The applicability of spent microalgal biomass residue for biogas and other applications to bring about zero-waste residue are discussed. Furthermore, techno-economic analysis (TEA), life cycle assessment (LCA) and challenges of microalgal biorefineries are discussed.

Current developments on the application of microbial carotenoids as an alternative to synthetic pigments

Microbial carotenoids have attracted rising interest from several industries as a sustainable alternative to substitute the synthetic ones. Traditionally, carotenoids available in the market are obtained by the chemical route using nonrenewable sources (petrochemicals), revealing the negative impact on the environment and consumers. The most promising developments in the upstream and downstream processes of microbial carotenoids are reviewed in this work. The use of agro-based raw materials for bioproduction, and alternative solvents such as biosolvents, deep eutectic solvents, and ionic liquids for the recovery/polishing of microbial carotenoids were also reviewed. The principal advances in the field, regarding the biorefinery and circular economy concepts, were also discussed for a better understanding of the current developments. This review provides comprehensive overview of the hot topics in the field besides an exhaustive analysis of the main advantages/drawbacks and opportunities regarding the implementation of microbial carotenoids in the market.

Prospects of Microalgae for Biomaterial Production and Environmental Applications at Biorefineries

Microalgae are increasingly viewed as renewable biological resources for a wide range of chemical compounds that can be used as or transformed into biomaterials through biorefining to foster the bioeconomy of the future. Besides the well-established biofuel potential of microalgae, key microalgal bioactive compounds, such as lipids, proteins, polysaccharides, pigments, vitamins, and polyphenols, possess a wide range of biomedical and nutritional attributes. Hence, microalgae can find value-added applications in the nutraceutical, pharmaceutical, cosmetics, personal care, animal food, and agricultural industries. Microalgal biomass can be processed into biomaterials for use in dyes, paints, bioplastics, biopolymers, and nanoparticles, or as hydrochar and biochar in solid fuel cells and soil amendments. Equally important is the use of microalgae in environmental applications, where they can serve in heavy metal bioremediation, wastewater treatment, and carbon sequestration thanks to their nutrient uptake and adsorptive properties. The present article provides a comprehensive review of microalgae specifically focused on biomaterial production and environmental applications in an effort to assess their current status and spur further deployment into the commercial arena.

Microalgae as source of functional ingredients in new-generation foods: challenges, technological effects, biological activity, and regulatory issues

Microalgae feasibility as food ingredients or source of nutrients and/or bioactive compounds and their health effects have been widely studied. This review aims to provide an overview of the use of microalgae biomass in food products, the technological effects of its incorporation, and their use as a source of health-promoting bioactive compounds. In addition, it presents the regulatory aspects of commercialization and consumption, and the main trends and market challenges Microalgae have stood out as sources of nutritional compounds (polysaccharides, proteins, lipids, vitamins, minerals, and dietary fiber) and biologically active compounds (asthaxanthin, β-carotene, omega-3 fatty acids). The consumption of microalgae biomass proved to have several health effects, such as hypoglycemic activity, gastroprotective and anti-steatotic properties, improvements in neurobehavioral and cognitive dysfunction, and hypolipidemic properties. Its addition to food products can improve the nutritional value, aroma profile, and technological properties, with important alterations on the syneresis of yogurts, meltability in cheeses, overrun values and melting point in ice creams, physical properties and mechanical characteristics in crisps, and texture, cooking and color characteristics in pastas. However, more studies are needed to prove the health effects in humans, expand the market size, reduce the cost of production, and tighter constraints related to regulations.

Analysis of the lipid extraction performance in a cascade process for Scenedesmus almeriensis biorefinery

BACKGROUND

Microalgae have attracted considerable interest due to their ability to produce a wide range of valuable compounds. Pulsed Electric Fields (PEF) has been demonstrated to effectively disrupt the microalgae cells and facilitate intracellular extraction. To increase the commercial viability of microalgae, the entire biomass should be exploited with different products extracted and valorized according to the biorefinery scheme. However, demonstrations of multiple component extraction in series are very limited in literature. This study aimed to develop an effective lipid extraction protocol from wet Scenedesmus almeriensis after PEF-treatment with 1.5 MJ·kgDW-1. A cascade process, i.e., the valorization of several products in row, was tested with firstly the collection of the released carbohydrates in the water fraction, then protein enzymatic hydrolysis and finally lipid extraction. Biomass processed with high pressure homogenization (HPH) on parallel, served as benchmark.

RESULTS

Lipid extraction with ethanol:hexane (1:0.41 vol/vol) offered the highest yields from the different protocols tested. PEF-treatment promoted extraction with almost 70% of total lipids extracted against 43% from untreated biomass. An incubation step after PEF-treatment, further improved the yields, up to 83% of total lipids. Increasing the solvent volume by factor 2 offered no improvement. In comparison, extraction with two other systems utilizing only ethanol at room temperature or elevated at 60 °C were ineffective with less than 30% of total lipids extracted. Regarding cascade extraction, carbohydrate release after PEF was detected albeit in low concentrations. PEF-treated samples displayed slightly better kinetics during the enzymatic protein hydrolysis compared to untreated or HPH-treated biomass. The yields from a subsequent lipid extraction were not affected after PEF but were significantly increased for untreated samples (66% of total lipids), while HPH displayed the lowest yields (~ 49% of total lipids).

CONCLUSIONS

PEF-treatment successfully promoted lipid extraction from S. almeriensis but only in combination with a polar:neutral co-solvent (ethanol:hexane). After enzymatic protein hydrolysis in cascade processing; however, untreated biomass displayed equal lipid yields due to the disruptive effect of the proteolytic enzymes. Therefore, the positive impact of PEF in this scheme is limited on the improved reaction kinetics exhibited during the enzymatic hydrolysis step.

Marine diatom Thalassiosira weissflogii based biorefinery for co-production of eicosapentaenoic acid and fucoxanthin

Diatom algae can produce bioactive compounds like fucoxanthin (FX) and ecosapentaenoic acid (EPA) which are of high demand in pharmaceutical and nutraceutical industries. Here, the influence of different light regimes in combination with major nutrients on growth, FX and EPA production by marine diatom Thalassiosira weissflogii were investigated. Batch cultures of T. weissflogii were illuminated under blue (BL), red (RL) and white (WL) light at two intensities. BL regime resulted in higher cell density with a specific growth rate of 2.49µ. Lipid productivity and lipid % as dry cell weight (DCW) was considerably higher in BL with EPA productivity of 33.4 mg L^-1d^-1. Fucoxanthin content as % DCW reached 0.95 (BL), 0.75 (RL) and 0.81 (WL) at mid exponential growth phase. The results further prove the plasticity of diatoms and provide a way for future metabolic engineering of T. weissflogii for potential microalgal bio-refinery for combined EPA and FX production.

Biological Activity of Hydrophilic Extract of Chlorella vulgaris Grown on Post-Fermentation Leachate from a Biogas Plant Supplied with Stillage and Maize Silage

Algae are employed commonly in cosmetics, food and pharmaceuticals, as well as in feed production and biorefinery processes. In this study, post-fermentation leachate from a biogas plant which exploits stillage and maize silage was utilized as a culture medium for Chlorella vulgaris. The content of polyphenols in hydrophilic extracts of the Chlorella vulgaris biomass was determined, and the extracts were evaluated for their antioxidant activity (DPPH assay), antibacterial activity (against Escherichia coli, Lactobacillusplantarum, Staphylococcus aureus, Staphylococcus epidermidis) and antifungal activity (against Aspergillus niger, Candida albicans, Saccharomyces cerevisiae). The use of the post-fermentation leachate was not found to affect the biological activity of the microalgae. The aqueous extract of Chlorella vulgaris biomass was also observed to exhibit activity against nematodes. The results of this study suggest that Chlorella vulgaris biomass cultured on post-fermentation leachate from a biogas plant can be successfully employed as a source of natural antioxidants, food supplements, feed, natural antibacterial and antifungal compounds, as well as in natural methods of plant protection.

Trends in Seaweed Extract Based Biostimulants: Manufacturing Process and Beneficial Effect on Soil-Plant Systems

The time when plant biostimulants were considered as "snake oil" is erstwhile and the skepticism regarding their agricultural benefits has significantly faded, as solid scientific evidences of their positive effects are continuously provided. Currently plant biostimulants are considered as a full-fledged class of agri-inputs and highly attractive business opportunity for major actors of the agroindustry. As the dominant category of the biostimulant segment, seaweed extracts were key in this growing renown. They are widely known as substances with the function of mitigating abiotic stress and enhancing plant productivity. Seaweed extracts are derived from the extraction of several macroalgae species, which depending on the extraction methodology lead to the production of complex mixtures of biologically active compounds. Consequently, plant responses are often inconsistent, and precisely deciphering the involved mechanism of action remains highly intricate. Recently, scientists all over the world have been interested to exploring hidden mechanism of action of these resources through the employment of multidisciplinary and high-throughput approaches, combining plant physiology, molecular biology, agronomy, and multi-omics techniques. The aim of this review is to provide fresh insights into the concept of seaweed extract (SE), through addressing the subject in newfangled standpoints based on current scientific knowledge, and taking into consideration both academic and industrial claims in concomitance with market's requirements. The crucial extraction process as well as the effect of such products on nutrient uptake and their role in abiotic and biotic stress tolerance are scrutinized with emphasizing the involved mechanisms at the metabolic and genetic level. Additionally, some often overlooked and indirect effects of seaweed extracts, such as their influence on plant microbiome are discussed. Finally, the plausible impact of the recently approved plant biostimulant regulation on seaweed extract industry is addressed.