Overview and Challenges of Large-Scale Cultivation of Photosynthetic Microalgae and Cyanobacteria

Microalgae and cyanobacteria are diverse groups of organisms with great potential to benefit societies across the world. These organisms are currently used in food, feed, pharmaceutical and cosmetic industries. In addition, a variety of novel compounds are being isolated. Commercial production of photosynthetic microalgae and cyanobacteria requires cultivation on a large scale with high throughput. However, scaling up production from lab-based systems to large-scale systems is a complex and potentially costly endeavor. In this review, we summarise all aspects of large-scale cultivation, including aims of cultivation, species selection, types of cultivation (ponds, photobioreactors, and biofilms), water and nutrient sources, temperature, light and mixing, monitoring, contamination, harvesting strategies, and potential environmental risks. Importantly, we also present practical recommendations and discuss challenges of profitable large-scale systems associated with economical design, effective operation and maintenance, automation, and shortage of experienced phycologists.

Food Ingredients and Nutraceuticals from Microalgae: Main Product Classes and Biotechnological Production

Microalgal products are an emerging class of food, feed, and nutraceuticals. They include dewatered or dried biomass, isolated pigments, and extracted fat. The oil, protein, and antioxidant-rich microalgal biomass is used as a feed and food supplement formulated as pastes, powders, tablets, capsules, or flakes designed for daily use. Pigments such as astaxanthin (red), lutein (yellow), chlorophyll (green), or phycocyanin (bright blue) are natural food dyes used as isolated pigments or pigment-rich biomass. Algal fat extracted from certain marine microalgae represents a vegetarian source of n-3-fatty acids (eicosapentaenoic acid (EPA), docosahexaenoic acid (DHA), γ-linolenic acid (GLA)). Gaining an overview of the production of microalgal products is a time-consuming task. Here, requirements and options of microalgae cultivation are summarized in a concise manner, including light and nutrient requirements, growth conditions, and cultivation systems. The rentability of microalgal products remains the major obstacle in industrial application. Key challenges are the high costs of commercial-scale cultivation, harvesting (and dewatering), and product quality assurance (toxin analysis). High-value food ingredients are commonly regarded as profitable despite significant capital expenditures and energy inputs. Improvements in capital and operational costs shall enable economic production of low-value food products going down to fishmeal replacement in the future economy.

Comprehensive evaluation of microalgal based dairy effluent treatment process for clean water generation and other value added products

The current study demonstrates a comprehensive investigation on clean water generation from raw dairy wastewater (RDW) using a robust microalgal strain, Ascochloris sp. ADW007 and its growth, biomass, and lipid productivities in outdoor conditions. Microalgal treatment studies were conducted in column photobioreactor (CPB) and flat-pate photobioreactor (FPB), where the volumetric algal biomass productivity in RDW was significantly increased in both CPB (0.284 ± 0.0017 g/L/d) and FPB (0.292 ± 0.0121 g/L/d) as compared to synthetic mediums viz., BG11 and TAP, respectively, with enhanced lipid content. Maximum lipid accumulation of 33.40% was obtained within 7 d growth. The volumetric and areal lipid productivities in CPB and FPB were 94 mg/L/d and 5.597 g/m²/d, and 98 mg/L/d and 9.754 g/m²/d, respectively. Chemiflocculation, filtration, and centrifugation techniques were employed for harvesting microalgal biomass. Among the flocculants, 0.08% (w/v) FeCl₃ harvested >99% of algal cells within 5 min, while 0.03% (w/v) cetyl trimethyl ammonium bromide and 0.125% (w/v) sodium hydroxide harvested >96% of the cells in 30 and 60 min. After microalgal treatment, >80% of clean and odorless water was obtained with reduction in 94-96% of COD, 72-80% of nitrate and 80-97% of total phosphate, respectively. Highlights Utilization of 100% raw dairy wastewater without any treatment. Production of clean and odorless water for recycle and reuse. COD, nitrate and total phosphate reduction by 94-96%, 72-80%, and 80-97% after treatment. Microalgal treatment studies in simple column and flat-plate photobioreactors. Biomass and lipid production as other value added by-products.

High-added value products from microalgae and prospects of aquaculture wastewaters as microalgae growth media

Aquaculture plays an important role in human nutrition and economic development but is often expanded to the detriment of the natural environment. Several research projects, aimed at cultivating microalgae in aquaculture wastewaters (AWWs) to reduce organic loads and minerals, along with the production of microalgal cell mass and metabolic products, are underway. Microalgal cell mass is of high nutritional value and is regarded as a candidate to replace, partially at least, the fish meal in the fish feed. Also, microalgal cell mass is considered as a feedstock in the bio-fuel manufacture, as well as a source of high-added value metabolic products. The production of these valuable products can be combined with the reuse of AWWs in the light of environmental concerns related with the aquaculture sector. Many research papers published in the last decade demonstrate that plenty of microalgae species are able to efficiently grow in AWWs, mainly derived from fish and shrimp farms, and produce valuable metabolites reducing the AWW pollutant load. We conclude that bio-remediation of AWWs combining with the production of microalgae cell mass and specific metabolites is probably the most convenient and economical solution for AWWs management and can contribute to the sustainable growth of the aquaculture.

Semicontinuous system for the production of recombinant mCherry protein in Chlamydomonas reinhardtii

Biotechnology advances have allowed bacteria, yeasts, plants, mammalian and insect cells to function as heterologous protein expression systems. Recently, microalgae have gained attention as an innovative platform for recombinant protein production, due to low culture media cost, compared to traditional systems, as well as the fact that microalgae such as Chlamydomonas reinhardtii are considered safe (GRAS) by the Food and Drug Administration (FDA). Previous studies showed that recombinant protein production in traditional platforms by semicontinuous process increased biomass and bio product productivity, when compared to batch process. As there is a lack of studies on semicontinuous process for recombinant protein production in microalgae, the production of recombinant mCherry fluorescent protein was evaluated by semicontinuous cultivation of Chlamydomonas reinhardtii in bubble column photobioreactor. This semicontinuous cultivation process was evaluated in the following conditions: 20%, 40%, and 60% culture portion withdrawal. The highest culture withdrawal percentage (60%) provided the best results, as an up to 161% increase in mCherry productivity (454.5 RFU h-1 - Relative Fluorescence Unit h-1 ), in comparison to batch cultivation (174.0 RFU h-1 ) of the same strain. All cultivations were carried out for 13 days, at pH 7, temperature 25°C and, by semicontinuous process, two culture withdrawals were taken during the cultivations. Throughout the production cycles, it was possible to obtain biomass concentration up to 1.36 g L-1 .

Optical Camera Communication as an Enabling Technology for Microalgae Cultivation

Optical Camera Communication (OCC) systems have a potential application in microalgae production plants. In this work, a proof-of-concept prototype consisting of an artificial lighting photobioreactor is proposed. This reactor optimises the culture's photosynthetic efficiency while transmitting on-off keying signals to a rolling-shutter camera. Upon reception, both signal decoding and biomass concentration sensing are performed simultaneously using image processing techniques. Moreover, the communication channel's theoretical modelling, the data rate system's performance, and the plant distribution requirements and restrictions for a production-scale facility are detailed. A case study is conducted to classify three different node arrangements in a real facility, considering node visibility, channel capacity, and space exploitation. Finally, several experiments comprising radiance evaluation and Signal-to-Noise Ratio (SNR) computation are performed at different angles of view in both indoor and outdoor environments. It is observed that the Lambertian-like emission patterns are affected by increasing concentrations, reducing the effective emission angles. Furthermore, significant differences in the SNR, up to 20 dB, perceived along the illuminated surface (centre versus border), gradually reduce as light is affected by greater dispersion. The experimental analysis in terms of scattering and selective wavelength attenuation for green (Arthrospira platensis) and brown (Rhodosorus marinus) microalgae species determines that the selected strain must be considered in the development of this system.

Orange Peel Waste as Feedstock for the Production of Glycerol-Free Biodiesel by the Microalgae Nannochloropsis oculata

The bioconversion of agri-food waste into high-value products is gaining growing interest worldwide. Orange peel waste (OPW) is the main by-product of orange juice production and contains high levels of moisture and carbohydrates. In this study, the orange waste extract (OWE) obtained through acid hydrolysis of OPW was used as a substrate in the cultivation of the marine microalgae Nannochloropsis oculata. Photoheterotrophic (PH) and Photoautotrophic (PA) cultivations were performed in OWE medium and f/2 medium (obtained by supplementing OWE with macro- and micronutrients of f/2 medium), respectively, for 14 days. The biomass yields in PA and PH cultures were 390 mg L-1 and 450 mg L-1, while oil yields were 15% and 28%, respectively. The fatty acid (FA) profiles of PA cultures were mostly represented by saturated (43%) and monounsaturated (46%) FAs, whereas polyunsaturated FAs accounted for about 10% of the FAs. In PH cultures, FA profiles changed remarkably, with a strong increase in monounsaturated FAs (77.49%) and reduced levels of saturated (19.79%) and polyunsaturated (2.72%) FAs. Lipids obtained from PH cultures were simultaneously extracted and converted into glycerol-free biodiesel using an innovative microwave-assisted one-pot tandem protocol. FA methyl esters were then analyzed, and the absence of glycerol was confirmed. The FA profile was highly suitable for biodiesel production and the microwave-assisted one-pot tandem protocol was more effective than traditional extraction techniques. In conclusion, N. oculata used OWE photoheterotrophically, resulting in increased biomass and oil yield. Additionally, a more efficient procedure for simultaneous oil extraction and conversion into glycerol-free biodiesel is proposed.

Harnessing Artificial Intelligence to Revolutionize Microalgae Biotechnology: Unlocking Sustainable Solutions for High-Value Compounds and Carbon Neutrality

Microalgae offer significant potential in diverse fields, including biofuels, carbon capture, and high-value bioproducts. However, optimizing and scaling microalgae cultivation systems present several challenges due to the dynamic interactions among environmental factors such as light intensity, temperature, pH, nutrient concentration, and CO2 levels, as well as species-specific biological variability. Recent advancements in artificial intelligence (AI), particularly machine learning (ML) and automation, have provided innovative solutions to these challenges. This review explored the role of AI in enhancing microalgae technology, focusing on optimizing cultivation conditions, improving CO2 capture, maximizing biomass production, and automating system processes. Key case studies highlight successful applications of AI in biofuel production, carbon capture projects, and high-value compound manufacturing. Key case studies demonstrate that AI-driven models can increase biomass productivity by up to 15-57%, improve CO2 biofixation efficiency, and enhance lipid and high-value compound yields by more than 20-43% compared to traditional methods. Additionally, we discussed the limitations of current AI models, particularly in data availability and species-specific variability, and suggested future research directions to enhance the integration of AI and microalgae systems. By leveraging AI's potential, microalgae technologies can become more efficient, scalable, and economically viable, addressing global sustainability challenges such as energy production and climate change mitigation.

The Influence of Elevated CO2 Concentrations on the Growth of Various Microalgae Strains

The influence of elevated CO₂ concentrations on the growth and viability of various microalgae strains was studied. Arthrospira platensis, Chlorella ellipsoidea, Chlorella vulgaris, Gloeotila pulchra, and Elliptochloris subsphaerica were tested. The cultivation of microalgae was carried out at constant CO₂ concentrations (0.04, 3, 6, or 9%-sequentially from lower to higher concentrations), under constant (24 h·day^-1) illumination with an intensity of 74.3 µmol quanta·m^-2·s^-1, and a constant temperature of 23.5 ± 0.5 °C. The optical density of the microalgae biomass, pH, and the chemical composition of the culture medium were measured. Microscopy (including the cytochemical microscopic method) was conducted to monitor the state of the microalgae. The highest biomass growth rate (0.37 g·L^-1·day^-1), among all experiments, was achieved for Chlorella vulgaris at CO₂ = 3% and for Chlorella ellipsoidea at CO₂ = 6 and 9%. The lowest growth rate (0.12 g·L^-1·day^-1) was achieved for Arthrospira platensis at CO₂ = 3 and 9%. The microscopy results showed the absence or a minimum number of dead cells of the strains under selected conditions. The ability to maintain the viability of cultures up to significant concentrations of CO₂ = 9% was due to adaptation (gradual increase in CO₂ concentrations in the experiments).

A Tool for On-Line Monitoring Microalgal Bioprocesses Based on Gas Balance Analysis

This study introduces a novel method for monitoring microalgae growth and evaluating mass transfer efficiency in photobioreactors, specifically under non-limiting and controlled growth conditions. By leveraging data on elemental composition, gas transfer rates, and oxygen production rate, the method estimates biomass growth and assesses gas-liquid mass transfer coefficients. The approach uses indirect measurements to infer critical parameters, including biomass concentration, total inorganic carbon, and nitrogen levels. Results demonstrate accurate predictions of biomass growth and carbon dynamics, along with effective characterization of mass transfer coefficients. This method offers a robust tool for optimizing photobioreactor performance and enhancing process control.

Enhancing algal growth and nutrient recovery from anaerobic digestion piggery effluent by an integrated pretreatment strategy of ammonia stripping and flocculation

Anaerobic digestion piggery effluent (ADPE) with a quite high ammonium (NH₄ ⁺) concentration and turbidity (dark brown color) generally requires high dilution before microalgae cultivation, owing to its NH₄ ⁺ toxicity and color inhibition to algal growth. An integrated pretreatment strategy of ammonia stripping and chemical flocculation may be a more practical pretreatment procedure for enhancing algae yield and nutrient recovery from anaerobic digestion piggery effluent. In this study, we determined the optimum pretreatment strategy of anaerobic digestion piggery effluent for subsequent microalgae cultivation and nutrient recovery. The results showed that the integrated anaerobic digestion piggery effluent pretreatment strategy of high-temperature ammonia stripping and chemical flocculation at a mixed dosage of 2 g L^-1 polyaluminum chloride (PAC) and 40 mg L^-1 cationic polyacrylamide (C-PAM), and 50 mg L^-1 ammonium nitrogen (NH₄ ⁺-N) enrichment provided maximum algal yield (optical density = 1.8) and nutrient removal (95.2%, 98.7%, 99.3%, and 78.5% for the removal efficiencies of total nitrogen, NH₄ ⁺-N, total phosphorus, and chemical oxygen demand, respectively) from anaerobic digestion piggery effluent. The integrated pretreatment strategy is expected to become a more practical pretreatment procedure for enhancing algae yield and nutrient recovery from anaerobic digestion piggery effluent.

Improving the Quality of Reclaimed Water via Applying Spirulina platensis to Eliminate Residual Nitrate

The application of reclaimed water has been recognized as the key approach for alleviating water scarcity, while its low quality, such as high nitrogen content, still makes people worry about the corresponding ecological risk. Herein, we investigated the feasibility of removing residual nitrate from reclaimed water by applying Spirulina platensis. It is found that 15 mg/L total nitrogen could be decreased to 1.8 mg/L in 5 days, equaling 88.1 % removal efficiency under the optimized conditions. The deficient phosphorus at 0.5-1.0 mg/L was rapidly eliminated but was already sufficient to support nitrate removal by S. platensis. The produced ammonia is generally below 0.2 mg/L, which is much lower than the standard limit of 5 mg/L. In such a nutrient deficiency condition, S. platensis could maintain biomass growth well via photosynthesis. The variation of pigments, including chlorophyll a and carotenoids, suggested a certain degree of influences of illumination intensity and phosphorus starvation on microalgae. The background cations Cu²⁺ and Zn²⁺ exhibited significant inhibition on biomass growth and nitrate removal; thus, more attention needs to be paid to the further application of microalgae in reclaimed water. Our results demonstrated that cultivation of S. platensis should be a very promising solution to improve the quality of reclaimed water by efficiently removing nitrate and producing biomass.

Chlorella sp. as a promising protein source: insight to novel extraction techniques, nutritional and techno-functional attributes of derived proteins

Amidst the mounting environmental crises and ever-increasing global population, the quest for sustainable food production and resource utilization solutions has taken center stage. Microalgae, with Chlorella species at the forefront, present a promising avenue. They serve as a bountiful protein source and can be conveniently grown in waste streams, thereby tackling food security, environmental sustainability, and economic feasibility. This article embarks on a comprehensive journey through recent research on Chlorella by shedding light on its unique characteristics, its market value, cultivation techniques, and harvesting methods. It also delves into traditional and innovative extraction methods, underscoring the hurdles and breakthroughs in achieving high protein yields from the Chlorella biomass. Moreover, exploration of the protein's nutritional properties, bioactive peptides, and techno-functional attributes, enhance its potential for food applications. Further, this review also examines current market trends in consumer acceptance of this alternative protein and discusses strategies for reducing greenhouse gas emissions in their production. By providing invaluable insights into the current status and future prospects of Chlorella protein, it aspires to make a significant contribution to the ongoing dialogue on sustainable food production and resource management.

Nannochloris sp. JB17 as a Potential Microalga for Carbon Capture and Utilization Bio-Systems: Growth and Biochemical Composition Under High Bicarbonate Concentrations in Fresh and Sea Water

Nannochloris sp. JB17 has been identified as an interesting microalgal species that can tolerate high salinity and high bicarbonate concentrations. In this study, Nannochloris sp. JB17 was long-term adapted to increased bicarbonate concentrations (10-60 g NaHCO3 per L) in fresh or sea-water-based growing media. This study aimed to evaluate its growth performance and biochemical composition under different cultivation conditions. The highest biomass production (1.24-1.3 g/L) achieved in the study was obtained in fresh water media supplemented with 40 g/L and 60 g/L NaHCO3, respectively. Total protein content fluctuated at similar levels among the different treatments (32.4-38.5%), displaying good essential amino acids indices of 0.85-1.02, but with low in vitro protein digestibility (15-20%) rates. Total lipids did not show any significant alteration among the different NaHCO3 concentrations in both fresh and sea water (12.6-13.3%) but at increased sodium strength, a significant increase in unsaturated lipids and in particular a-linolenic acid (C18:3) and linoleic acid (C18:2) was observed. Carbohydrate content also ranged at very similar levels among the cultures (26-30.9%). The main fraction of carbohydrates was in the type of neutral sugars ranging from around 72% to 80% (of total carbohydrates), while uronic acids were in negligible amounts. Moreover, Nannochloris sp. showed that it contained around 8-9% sulfated polysaccharides. Since the microalgae display good growth patterns at high bicarbonate concentrations, they could be a potential species for microalgal-based carbon capture and utilization systems.

Flocculation of Micractinium reisseri for successful harvesting and potential use

This study includes Micractinium reisseri cultivation in artificial saline medium (ASM). With the aim of harvesting the bulk M. reisseri biomass, an experiment was set up at a bench scale to evaluate the best flocculation technique with the least compromising biomass and lipid loss. The flocculation efficiencies for the M. reisseri biomass have been studied using the auto-, bio-, and chemical-flocculation methods. Different concentrations of chitosan for the biological method and alum for the chemical method were added in M. reisseri culture growing in the liquid ASM. The optimal concentration with the highest biomass and oil collection was determined for each method. In the biological method, the highest (96.44%) and lowest (67.88%) flocculation efficiencies were observed by adding 15 and 2 mg of chitosan, respectively, and in the chemical method, the highest (97.2%) and lowest (35.4%) flocculation efficiencies were observed by adding 150 and 50 mg of alum, respectively. The auto-flocculation method shows the highest efficiency (97.8%) among all the tests. The oil yield from the three highest biomasses was 2.60, 1.51, and 1.08% in the auto-, bio-, and chemical-flocculation methods, respectively. The time taken for auto-, bio-, and chemical-flocculation was 48, 4, and 1 h, respectively.

Culturable Yeast Diversity Associated with Industrial Cultures of the Microalga Microchloropsis gaditana and Their Ability to Produce Lipids and Biosurfactants

The marine oleaginous microalga Microchloropsis gaditana (formerly Nannochloropsis gaditana) exhibits a high capacity to thrive in a broad range of environmental conditions, being predominantly utilized as feed in aquaculture. This article reports the characterization of the culturable yeast population present during the scale-up process of M. gaditana cultivation at Necton S.A. facilities, from 5 L flasks until tubular photobioreactors. The 146 yeast isolates obtained, molecularly identified based on D1/D2 and ITS nucleotide sequences, belong to the species Rhodotorula diobovata, R. mucilaginosa, R. taiwanensis, R. sphaerocarpa, Vishniacozyma carnescens, Moesziomyces aphidis, and Meyerozyma guilliermondii. The yeast abundance was found to increase throughout upscaling stages. The yeast populations isolated from microalgal cultures and water samples share phylogenetically close isolates, indicating a possible common source. The impressive high percentage of red yeasts isolated (90%) is consistent with the recognized role of carotenoid pigments in yeast photoprotection. Sixty yeast isolates were tested for lipid (Nile Red staining) and biosurfactant (oil drop dispersion and emulsification index) production. Results revealed that these capacities are common features. Microbial lipids and biosurfactants have promising biotechnological applications. Moreover, biosurfactants can fulfill various physiological roles and provide advantages in natural environments contributing to the promising use of yeasts as probiotics in microalgae production.