Lab-scale photobioreactor systems: principles, applications, and scalability

Integrated model of sequential anaerobic and algal membrane bioreactor (A2MBR) system for wastewater reuse and resource recovery

We developed a novel integrated model for describing the A2MBR system, treating municipal wastewater for resource recovery. The model couples an anaerobic membrane bioreactor (AnMBR) with an algal photo membrane bioreactor (APMBR). The AnMBR details organic matter fractionation and its effect on SMP and EPS, while the APMBR incorporates alga-bacteria interaction, light, temperature, and membrane separation effects. While showing good agreement between simulated and measured values, results suggest that higher sludge retention time (SRT) drives COD removal, promoting biogas production in the AnMBR (2.5-3 days HRT and 60-90 days SRT not to exceed a 25 g MLSS/l). For the APMBR, shorter HRTs and longer SRTs promote microalgae growth, and longer HRTs enhance nutrient removal (maximum nutrient removal at 3 days HRT and 10 days SRT). Long-term operational data are needed to validate the proposed model. This modeling tool is valuable for modelers describing anaerobic/algal membrane processes for multi-purpose wastewater treatment.

Microfluidic method for rapidly determining the protein and lipid yield of microalgae

Microalgae are a promising source of green energy. They produce valuable bioproducts, such as proteins and lipids, and remove atmospheric carbon. In this study, we developed a microfluidic chip for culturing and screening for microalgae with high protein and lipid contents. Over 30 microalgae cultures can be grown in parallel in hanging drops on the chip and separately subjected to various experimental treatments, such as random mutations or different light levels. The microfluidic chip has a simple design and was fabricated from optically transparent polymethyl methacrylate; it could be easily operated without complex equipment (e.g., a syringe pump). The design was experimentally validated by culturing Cyanidium sp. and performing in-situ fluorescein measurements of its protein content after various ultraviolet and illumination treatments; significant increases in protein yield were observed for selected mutants (approximately 36 %) and further increased with optimized illumination (2500 lux; approximately 35 %). Moreover, Botryococcus braunii cultured in hanging drops that were separately immobilized using a biocompatible agarose gel for in-situ Raman spectroscopy measurements that rapidly determined the lipid composition. Our developed single-drop Raman spectroscopy method not only quantified the lipid content but also revealed its detailed chemical composition. In summary, the designed microfluidic chip is suitable for in-situ fluorescent assays and Raman microspectroscopy and is a compelling solution for high-throughput screening of algal lipids and proteins, reducing the labor required for breeding mutant algae and optimizing algal cultivation.

Sustainable treatment of sugarcane vinasse using Chlorella sp. in scalable airlift flat-panel photobioreactors: nutrient removal and biomass valorization

The global production of sugarcane ethanol generates vast amounts of vinasse, a liquid waste by-product requiring treatment to mitigate environmental impacts. Using vinasse as a feedstock for microalgae cultivation offers a sustainable alternative. This study evaluates the performance of the native strain Chlorella sp. MC18 in internal-loop airlift flat-panel photobioreactors (PBR) for treating industrial raw sugarcane vinasse (SCV) while producing biomass. Cultures were grown in diluted, centrifugation-pretreated SCV (5-25% v/v) as the sole nutrient source, with CO2 supplied by aeration. The best results were obtained with 10% SCV. Nutrient removal efficiencies reached up to 99% for nitrates and 90% for phosphates, with reduction in chemical oxygen demand (COD) exceeding 75% at 5-10% SCV. The highest specific growth rate (0.711 day-1) and biomass productivity (116 mg L-1 day-1) occurred at 10% SCV, maintaining stable pH control (8.2-8.5). The PBR design enabled scalable, reproducible growth kinetics while minimising biofouling. Biomass from 10% SCV holds significant potential for energy recovery (20.24 kJ g-1) and production of high-value product pools (lipids, carbohydrates, proteins, and carotenoids). These results demonstrate the feasibility of scaling up the PBR design for integrated vinasse treatment with Chlorella and biomass valorisation, reinforcing the concept of an agro-industrial sector biorefinery.

Synthetic Biology Strategies and Tools to Modulate Photosynthesis in Microbes

The utilization of photosynthetic microbes, such as cyanobacteria and microalgae, offers sustainable solutions to addressing global resource shortages and pollution. While these microorganisms have demonstrated significant potential in biomanufacturing, their industrial application is limited by suboptimal photosynthetic efficiency. Synthetic biology integrates molecular biology, systems biology, and engineering principles to provide a powerful tool for elucidating photosynthetic mechanisms and rationally optimizing photosynthetic platforms. This review summarizes recent advancements in regulating photosynthesis in cyanobacteria and microalgae via synthetic biology, focusing on strategies to enhance light energy absorption, optimize electron transport chains, and improve carbon assimilation. Furthermore, we discuss key challenges in translating these genetic modifications to large-scale bioproduction, highlighting specific bottlenecks in strain stability, metabolic burden, and process scalability. Finally, we propose potential solutions, such as AI-assisted metabolic engineering, synthetic microbial consortia, and next-generation photobioreactor designs, to overcome these limitations. Overall, while synthetic biology holds great promise for enhancing photosynthetic efficiency in cyanobacteria and microalgae, further research is needed to refine genetic strategies and develop scalable production systems.

Impact of nutrient deficiency and harvesting strategy on biomass and phycocyanin production in Spirulina cultures

Recent research has focused on issues related to contamination, nutrient availability, and strain selection, but there has been insufficient focus on harvesting research. This study employed an integrated continuous cultivation and harvesting strategy for a Spirulina microalgae biorefinery. The effects of nutrient-deficiency, harvesting ratio, and NaNO3 addition on biomass concentration and productivity and phycocyanin accumulation of Spirulina were investigated. The lowest biomass productivity of 0.015 g/L/day was observed in Spirulina cultivated in NaNO3 deficient medium. A harvesting ratio of 10% showed a consistent range of harvested dry biomass weight (0.20-0.22 g). Addition of 2.50 g/L NaNO3 resulted in a significant increase in C-phycocyanin (C-PC) and allophycocyanin (APC) concentration from 34.37 mg/g to 68.35 and 27.08 to 33.23 mg/g, respectively. Biomass productivity of 1-L and 10-L batch culture was found to be 0.23 g/L/d and 0.21 g/L/d, respectively. Both 1-L and 10-L batch cultures showed a significant increase in phycocyanin accumulation due to the addition of 2.50 g/L of NaNO3. These findings highlight the feasibility of continuous cultivation and optimized harvesting for scalable biomass and phycocyanin production, offering valuable insights for industrial biorefineries that seek to enhance microalgae-based bioactive compound extraction.

An automated high-throughput lighting system for screening photosynthetic microorganisms in plate-based formats

The capacity of photosynthetic microorganisms to fix carbon dioxide into biomass positions them as promising cell factories for sustainable biomanufacturing. However, limitations in screening throughput hinder the identification of enzymes, strains, and growth conditions needed to realize this potential. Here we present a microplate-based high-throughput cultivation system that can be integrated into existing automation infrastructure and supports growth of both prokaryotic and eukaryotic photosynthetic microorganisms. We validate this system by optimizing BG-11 medium compositions for Synechococcus elongatus UTEX 2973, Chlamydomonas reinhardtii UTEX 90 and Nostoc hatei CUBC1040, resulting in growth rates increases of 38.4% to 61.6%. We also identify small molecules that influence growth rates in Synechococcus elongatus UTEX 2973, including candidate compounds for growth rate increase and dozens that prevent growth. The sensitivity, throughput, and extensibility of this system support screening, strain isolation, and growth optimization needed for the development of photosynthetic microbial cell factories.

Advancements and challenges in microalgal protein production: A sustainable alternative to conventional protein sources

The increasing global demand for sustainable protein sources necessitates the exploration of alternative solutions beyond traditional livestock and crop-based proteins. Microalgae present a promising alternative due to their high protein content, rapid biomass accumulation, and minimal land and water requirements. Furthermore, their ability to thrive on non-arable land and in wastewater systems enhances their sustainability and resource efficiency. Despite these advantages, scalability and economical feasibility remain major challenges in microalgal protein production. This review explores recent advancements in microalgal protein cultivation and extraction technologies, including pulsed electric field, ultrasound-assisted extraction, enzyme-assisted extraction, and microwave-assisted extraction. These innovative techniques have significantly improved protein extraction efficiency, purity, and sustainability, while addressing cell wall disruption and protein recovery challenges. Additionally, the review examines protein digestibility and bioavailability, particularly in the context of human nutrition and aquafeed applications. A critical analysis of life cycle assessment studies highlights the environmental footprint and economical feasibility of microalgal protein production compared to conventional protein sources. Although microalgal protein production requires significant energy inputs, advancements in biorefinery approaches, carbon dioxide sequestration, and industrial integration can help mitigate these limitations. Finally, this review outlines key challenges and future research directions, emphasizing the need for cost reduction strategies, genetic engineering for enhanced yields, and industrial-scale process optimization. By integrating innovative extraction techniques with biorefinery models, microalgal proteins hold immense potential as a sustainable, high-quality protein source for food, feed, and nutraceutical applications.

Microalgae and biogas: a boon to energy sector

The global energy generation market immensely depends on fossil fuels which balances our survival on this planet. Energy can be called as the "master element" for our daily needs, starting from household power supply, agricultural purpose, automobile and transportation, industrial workload to economic and research domains. Fuel switching initiatives are being adapted by environmentalist and scientists to bring a novel sustainable source of energy. An environment and renewable alternative to fossil fuels are a must. Over the years, the world has shifted toward generating green fuels immensely. One such potential alternative to fossil fuels are biogases. Being versatile and renewable in nature, it has drawn immense attention globally. Despite having such potentials there exist some major drawbacks which mainly deal with the starting material. One such source for biogases can be microalgae. Microalgae based biogas production can produce huge amount of energy and that has been implemented by many foreign countries and their companies. Despite being in use in many countries, there are issues which needs to be addressed which will overall improve the biogas potential from microalgae even more. This review mainly focuses on generation of biogas from microalgae as a feedstock which are very economical and sustainable in its nature, presenting improvement strategies which can be impended to boost the over biogas sector globally.

Integration of Fluorescence Spectroscopy into a Photobioreactor for the Monitoring of Cyanobacteria

Phytoplankton are essential to aquatic ecosystems but can cause harmful algal blooms (HABs) that threaten water quality, aquatic life, and human health. Developing new devices based on spectroscopic techniques offers a promising alternative for rapid and accurate monitoring of aquatic environments. However, phytoplankton undergo various physiological changes throughout their life cycle, leading to alterations in their optical properties, such as autofluorescence. In this study, we present a modification of a low-cost photobioreactor designed to implement fluorescence spectroscopy to analyze the evolution of spectral signals during phytoplankton growth cycles. This device primarily facilitates the characterization of changes in autofluorescence, providing valuable information for the development of future spectroscopic techniques for detecting and monitoring phytoplankton. Additionally, real-time testing was performed on cyanobacterial cultures, where changes in autofluorescence were observed under different conditions. This work demonstrates a cost-effective implementation of spectroscopic techniques within a photobioreactor, offering a preliminary analysis for the future development of functional field devices for monitoring aquatic ecosystems.

Comparing continuous and perfusion cultivation of microalgae on recirculating aquaculture system effluent water

Effluent water from recirculating aquaculture systems (RAS) contains nutrients from fish excrements and leftover feed. This study investigated the nutrient remediation potential from RAS effluent water through microalgae cultivation in 25 L tubular reactors. We compared nutrient uptake and biomass productivity in continuous and perfusion cultivation modes for freshwater, brackish water and saltwater. Stable high biomass densities were achieved with additional nitrate during continuous cultivation (up to 3.88 g L-1) or by membrane filtration during perfusion cultivation (up to 3.59 g L-1). A life cycle assessment (LCA) compared the two different cultivation modes in terms of environmental sustainability on a 1 ha scale. The LCA and preliminary economic assessment showed that perfusion cultivation appears to have a lower environmental impact for relatively low nutrient concentrations, but additional equipment and higher energy demands are leading to increased operational (+6 %) and capital expenses (up to +60 %).

A microfluidic system for the cultivation of cyanobacteria with precise light intensity and CO2 control: enabling growth data acquisition at single-cell resolution

Quantification of cell growth is central to any study of photoautotrophic microorganisms. However, cellular self-shading and limited CO2 control in conventional photobioreactors lead to heterogeneous conditions that obscure distinct correlations between the environment and cellular physiology. Here we present a microfluidic cultivation platform that enables precise analysis of cyanobacterial growth with spatio-temporal resolution. Since cyanobacteria are cultivated in monolayers, cellular self-shading does not occur, allowing homogeneous illumination and precise knowledge of the photon-flux density at single-cell resolution. A single chip contains multiple channels, each connected to several hundred growth chambers. In combination with an externally applied light gradient, this setup enables high-throughput multi-parameter analysis in short time. In addition, the multilayered microfluidic design allows continuous perfusion of defined gas mixtures. Transversal CO2 diffusion across the intermediate polydimethylsiloxane membrane results in homogeneous CO2 supply, with a unique exchange-surface to cultivation-volume ratio. Three cyanobacterial model strains were examined under various, static and dynamic environmental conditions. Phase-contrast and chlorophyll fluorescence images were recorded by automated time-lapse microscopy. Deep-learning trained cell segmentation was used to efficiently analyse large image stacks, thereby generating statistically reliable data. Cell division was highly synchronized, and growth was robust under continuous illumination but stopped rapidly upon initiating dark phases. CO2-Limitation, often a limiting factor in photobioreactors, was only observed when the device was operated under reduced CO2 between 50 and 0 ppm. Here we provide comprehensive and precise data on cyanobacterial growth at single-cell resolution, accessible for further growth studies and modeling.

Photobioreactor design utilizing procedural three-dimensional modelling and ray tracing

The design of photobioreactors for microalgae cultivation aims to achieve an architecture that allows the most efficient photosynthetic growth. The availability of light at wavelengths that are important for photosynthesis is therefore particularly crucial for reactor design. While testing different reactor types in practice is expensive, simulations could effectively limit the range of material and reactor design options. In this study, procedural three-dimensional modelling together with ray tracing was used to create virtual models of a conventional glass photobioreactor lit from the outside and a steel photobioreactor with embedded light sources. The measured transmittance and reflectance of Chlorella vulgaris culture were used as a basis for light interaction simulation, and spectral images of the same species were used to validate the simulation results. This type of simulation could have the potential for comparing different reactor architectures, geometries and light attenuation to facilitate the transition to large-scale cultivation. Our results show that the proposed simulator is usable in photobioreactor geometry design as well as in the estimation of available illumination on wavelengths where microalgae have strong absorption peaks, but the handling of light scattering still needs improvement. To the authors' best knowledge, this is the first attempt, not focused on a specific use case, to build a general photobioreactor design tool capable of estimating hyperspectral light attenuation in microalgae suspension. All software code and used datasets are made available for the reader as open source.

CFD modeling of CO2 fixation by microalgae cultivated in a lab scale photobioreactor

The green microalga Chlorella vulgaris has been studied for efficient fixation of carbon dioxide, CO2, from elevated concentrations of in-feed gas flows. In this work, a Computational Fluid Dynamics (CFD) model for algae cultivation including the dependence on CO2 concentration in liquid has been derived based on cultivation experiments of Chlorella vulgaris. The experiments were performed in a laboratory scale cylindrical stirred tank reactor with a range of enriched CO2 concentrations in-feed (0.04-50 %). The model provided by Béchet et al. (2015) for algae cultivation considering dependence on local light, algae concentration and temperature has been implemented for CFD and modified for comprising CO2 dependence. The model has been verified with experimental results for the algae productivity showing the proper trends for dissolved CO2 concentrations and algae concentrations. Thus, the developed CFD model can serve as a tool for evaluating photobioreactor performance for CO2 capture.

Improving productivity of citramalate from CO2 by Synechocystis sp. PCC 6803 through design of experiment

BACKGROUND

Cyanobacteria have long been suggested as an industrial chassis for the conversion of carbon dioxide to products as part of a circular bioeconomy. The slow growth, carbon fixation rates, and limits of carbon partitioning between biomass and product in cyanobacteria must be overcome to fully realise this industrial potential. Typically, flux towards heterologous pathways is limited by the availability of core metabolites. Citramalate is produced in a single enzymatic step through the condensation of the central metabolites pyruvate and acetyl-CoA; improvements in citramalate productivity can, therefore, be used as a measure of overcoming this limitation. Furthermore, citramalate is a useful biomaterial precursor and provides a route to renewable methyl methacrylate and poly(methyl methacrylate), which is often traded as Perspex or Plexiglas.

RESULTS

Here, we describe a phenomenon where the concerted optimisation of process parameters significantly increased citramalate production in Synechocystis sp. PCC 6803. Design of experiment principles were used to determine the optima for each parameter and the interplay between multiple parameters. This approach facilitated a ~ 23-fold increase in citramalate titre from initial unoptimised experiments. The process of scale-up from batch cultures to 0.5, 2, and 5 L photobioreactors is described. At the 2-L scale, citramalate titres from carbon dioxide reached 6.35 g/L with space-time yields of 1.59 g/L/day whilst 5-L PBRs yielded 3.96 ± 0.23 g/L with a productivity of 0.99 ± 0.06 g/L/day. We believe the decrease in productivity from 2-L to 5-L scale was likely due to the increased pathlength and shading for light delivery reducing incident light per cell. However, changes in productivity and growth characteristics are not uncommon when scaling up biotechnology processes and have numerous potential causes.

CONCLUSIONS

This work demonstrates that the use of a process parameter control regime can ameliorate precursor limitation and enhance citramalate production. Since pyruvate and/or acetyl-CoA give rise to numerous products of biotechnological interest, the workflow presented here could be employed to optimise flux towards other heterologous pathways. Understanding the factors controlling and thus increasing carbon partitioning to product will help progress cyanobacteria as part of a carbon-neutral circular bioeconomy. This is the first study using design of experiment to optimise overall carbon fixation rate and carbon partitioning to product, with the goal of improving the performance of a cyanobacterium as a host for biological carbon capture.

Microalgae-derived biolubricants: Challenges and opportunities

Lubricants are indispensable in the modern economy for controlling friction and wear across many industries. Traditional lubricants are derived from petroleum crude and can cause significant ecological impact if released into the environment. Microalgae have emerged as a potential alternative to petroleum crude for producing renewable and environmentally friendly biolubricants. This review systematically assesses recent developments in microalgal-based biolubricant production, including tribological performance, microalgae selection, cultivation, harvesting, lipid and polysaccharide extraction and conversion to biolubricants, and market development. Compared to petroleum-based lubricants in terms of tribological properties, biolubricants are compatible with most emerging applications, such as electric vehicles and wind turbines. Nevertheless, they are less thermally and chemically stable, thus, may not be suitable for some traditional applications such as internal combustion engines. Literature data corroborated in this study reveals an urgent need for further research to scale up microalgae production and lower the cost of biomass harvesting. While technologies for converting microalgae-derived lipids to biolubricants appear to be well established, additional work is necessary to also utilize polysaccharides as another key ingredient for producing biolubricants, especially for low-temperature applications. Extraction methods are well established but further research is also needed to reduce the ecological impact, especially to utilize green solvents and reduce solvent consumption. Additionally, future research should delve into the use of nanoparticles as effective additives to obtain microalgae-based biolubricants with superior properties. Finally, it is essential to standardize the labeling system of biolubricants to establish a global market.

Microalgae: a multifaceted catalyst for sustainable solutions in renewable energy, food security, and environmental management

This review comprehensively examines the various applications of microalgae, focusing on their significant potential in producing biodiesel and hydrogen, serving as sustainable food sources, and their efficacy in treating both municipal and food-related wastewater. While previous studies have mainly focused on specific applications of microalgae, such as biofuel production or wastewater treatment, this review covers these applications comprehensively. It examines the potential for microalgae to be applied in various industrial sectors such as energy, food security, and environmental management. By bridging these different application areas, this review differs from previous studies in providing an integrated and multifaceted view of the industrial applications of microalgae. Since it is essential to increase the productivity of the process to utilize microalgae for various industrial applications, research trends in different microalgae cultivation processes, including the culture system (e.g., open ponds, closed ponds) or environmental conditions (e.g., pH, temperature, light intensity) to improve the productivity of biomass and valuable substances was firstly analyzed. In addition, microalgae cultivation technologies that can maximize the biomass and valuable substances productivity while limiting the potential for contamination that can occur when utilizing these systems have been described to maximize CO2 reduction. In conclusion, this review has provided a detailed analysis of current research findings and technological innovations, highlighting the important role of microalgae in addressing global challenges related to energy, food supply, and waste management. It has also provided valuable insights into future research directions and potential commercial applications in several bio-related industries, and illustrated how important continued exploration and development in this area is to realize the full potential of microalgae.

Recent advancements in wastewater treatment via anaerobic fermentation process: A systematic review

This manuscript delves into the realm of wastewater treatment, with a particular emphasis on anaerobic fermentation processes, especially dark, photo, and dark-photo fermentation processes, which have not been covered and overviewed previously in the literature regarding the treatment of wastewater. Moreover, the study conducts a bibliometric analysis for the first time to elucidate the research landscape of anaerobic fermentation utilization in wastewater purification. Furthermore, microorganisms, ranging from microalgae to bacteria and fungi, emphasizing the integration of these agents for enhanced efficiency, are all discussed and compared. Various bioreactors, such as dark and photo fermentation bioreactors, including tubular photo bioreactors, are scrutinized for their design and operational intricacies. The results illustrated that using clostridium pasteurianum CH4 and Rhodopseudomonas palustris WP3-5 in a combined dark-photo fermentation process can treat wastewater to a pH of nearly 7 with over 90% COD removal. Also, integrating Chlorella sp and Activated sludge can potentially treat synthetic wastewater to COD, P, and N percentage removal rates of 99%,86%, and 79%, respectively. Finally, the paper extends to discuss the limitations and future prospects of dark-photo fermentation processes, offering insights into the road ahead for researchers and scientists.

Utilizing CO2 in industrial off-gas for microalgae cultivation: considerations and solutions

The utilization of microalgae to treat carbon dioxide (CO2)-rich industrial off-gas has been suggested as both beneficial for emissions reduction and economically favorable for the production of microalgal products. Common sources of off-gases include coal combustion (2-15% CO2), cement production (8-15% CO2), coke production (18-23% CO2), and ore smelting (6-7% CO2). However, industrial off-gas also commonly contains other acid gas components [typically nitrogen oxides (NOX) and sulfur dioxide (SO2)] and metals that could inhibit microalgae growth and productivity. To utilize industrial off-gas effectively in microalgae cultivation systems, a number of solutions have been proposed to overcome potential inhibitions. These include bioprospecting to identify suitable strains, genetic modification to improve specific cellular characteristics, chemical additions, and bioreactor designs and operating procedures.In this review, results from microalgae experiments related to utilizing off-gas are presented, and the outcomes of different conditions discussed along with potential solutions to resolve limitations associated with the application of off-gas.

Enhancing high-density microalgae cultivation via exogenous supplementation of biostimulant derived from onion peel waste for sustainable biodiesel production

Microalgae demonstrate significant potential as a source of liquid-based biofuels. However, increasing biomass productivity in existing cultivation systems is a critical prerequisite for their successful integration into large-scale operations. Thus, the current work aimed to accelerate the growth of C. vulgaris via exogenous supplementation of biostimulant derived from onion peel waste. Under the optimal growth conditions, which entailed a biostimulant dosage of 37.5% v/v, a pH of 3, an air flow rate of 0.4 L/min, and a 2% v/v inoculum harvested during the mid-log phase, yielded a maximum biomass concentration of 1.865 g/L. Under the arbitrarily optimized parameters, a comparable growth pattern was evident in the upscaled cultivation of C. vulgaris, underscoring the potential commercial viability of the biostimulant. The biostimulant, characterized through gas chromatography-mass spectrometry (GC-MS) analysis, revealed a composition rich in polyphenolic and organo-sulphur compounds, notably including allyl trisulfide (28.13%), methyl allyl trisulfide (23.04%), and allyl disulfide (20.78%), showcasing potent antioxidant properties. Additionally, microalgae treated with the biostimulant consistently retained their lipid content at 18.44% without any significant reduction. Furthermore, a significant rise in saturated fatty acid (SFA) content was observed, with C16:0 and C18:1 dominating both bench-scale (44.08% and 14.01%) and upscaled (51.12% and 13.07%) microalgae cultures, in contrast to the control group where C18:2 was prevalent. Consequently, SFA contents reached 54.35% and 65.43% in bench-scale and upscaled samples respectively, compared to 33.73% in the control culture. These compositional characteristics align well with the requirements for producing high-quality crude biodiesel.

A custom 3D printed paddlewheel improves growth in flat panel photobioreactor

One of the main challenges with using flat panel photobioreactors for algal growth is uneven mixing and settling of cells in corners, especially when bubbling is the only method used for mixing. In order to improve mixing in our flat panel reactor, we designed a custom paddlewheel. Paddlewheels are frequently used in outdoor algae raceway ponds to improve mixing and we are taking advantage of the same principle for mixing in the reactor. The paddlewheel is easily integrated into our PSI FMT150 1-L flat panel photobioreactor and is printed on a 3D printer using high temperature poly lactic acid (HT-PLA). With the inclusion of an annealing step, the paddlewheel is autoclavable. Addition of the paddlewheel in the reactor minimized cell settling and improved algal growth, as evidenced by a nearly 40% increase in oxygen production rates. Nutrient dispersion and utilization in the culture was also improved as evidenced by a corresponding 38% decrease in CO2 concentration. The paddlewheel device presented here is a cost-effective method for improving algal growth in a flat panel photobioreactor.

Modeling and optimization of biomass productivity of Chlorella vulgaris using response surface methodology, analysis of variance and machine learning for carbon dioxide capture

This study explores bioremediation's effectiveness in reducing carbon emissions through the use of microalgae Chlorella vulgaris, known for capturing carbon dioxide and producing biomass. The impact of temperature and light intensity on productivity and carbon dioxide capture was investigated, and cultivation conditions were optimized in a photobioreactor using response surface methodology (RSM), analysis of variance (ANOVA), and deep neural networks (DNN). The optimal conditions determined were 28.74 °C and 225 μmol/m2/s with RSM, and 29.55 °C and 226.77 μmol/m2/s with DNN, closely aligning with literature values (29 °C and 225 μmol/m2/s). DNN demonstrated superior performance compared to RSM, achieving higher accuracy due to its capacity to process larger datasets using epochs and batches. The research serves as a foundation to further in this field by demonstrating the potential of utilizing diverse mathematical models to optimize bioremediation conditions, and offering valuable insights to improve carbon dioxide capture efficiency in microalgae cultivation.

Photobioreactor configurations in cultivating microalgae biomass for biorefinery

Microalgae, highly prized for their protein, lipid, carbohydrate, phycocyanin, and carotenoid-rich biomass, have garnered significant industrial attention in the context of third-generation (3G) biorefineries, seeking sustainable alternatives to non-renewable resources. Two primarily cultivation methods, open ponds and closed photobioreactors systems, have emerged. Open ponds, favored for their cost-effectiveness in large-scale industrial production, although lacking precise environmental control, contrast with closed photobioreactors, offering controlled conditions and enhanced biomass production at the laboratory scale. However, their high operational costs challenge large-scale deployment. This review comprehensively examines the strength, weakness, and typical designs of both outdoor and indoor microalgae cultivation systems, with an emphasis on their application in terms of biorefinery concept. Additionally, it incorporates techno-economic analyses, providing insights into the financial aspects of microalgae biomass production. These multifaceted insights, encompassing both technological and economic dimensions, are important as the global interest in harnessing microalgae's valuable resources continue to grow.

The Role of Light on the Microalgae Biotechnology: Fundamentals, Technological Approaches, and Sustainability Issues

Light energy directly affects microalgae growth and productivity. Microalgae in natural environments receive light through solar fluxes, and their duration and distribution are highly variable over time. Consequently, microalgae must adjust their photosynthetic processes to avoid photo limitation and photoinhibition and maximize yield. Considering these circumstances, adjusting light capture through artificial lighting in the main culture systems benefits microalgae growth and induces the production of commercially important compounds. In this sense, this review provides a comprehensive study of the role of light in microalgae biotechnology. For this, we present the main fundamentals and reactions of metabolism and metabolic alternatives to regulate photosynthetic conversion in microalgae cells. Light conversions based on natural and artificial systems are compared, mainly demonstrating the impact of solar radiation on natural systems and lighting devices, spectral compositions, periodic modulations, and light fluxes when using artificial lighting systems. The most commonly used photobioreactor design and performance are shown herein, in addition to a more detailed discussion of light-dependent approaches in these photobioreactors. In addition, we present the principal advances in photobioreactor projects, focusing on lighting, through a patent-based analysis to map technological trends. Lastly, sustainability and economic issues in commercializing microalgae products were presented.

Towards industrial biological hydrogen production: a review

Increased production of renewable energy sources is becoming increasingly needed. Amidst other strategies, one promising technology that could help achieve this goal is biological hydrogen production. This technology uses micro-organisms to convert organic matter into hydrogen gas, a clean and versatile fuel that can be used in a wide range of applications. While biohydrogen production is in its early stages, several challenges must be addressed for biological hydrogen production to become a viable commercial solution. From an experimental perspective, the need to improve the efficiency of hydrogen production, the optimization strategy of the microbial consortia, and the reduction in costs associated with the process is still required. From a scale-up perspective, novel strategies (such as modelling and experimental validation) need to be discussed to facilitate this hydrogen production process. Hence, this review considers hydrogen production, not within the framework of a particular production method or technique, but rather outlines the work (bioreactor modes and configurations, modelling, and techno-economic and life cycle assessment) that has been done in the field as a whole. This type of analysis allows for the abstraction of the biohydrogen production technology industrially, giving insights into novel applications, cross-pollination of separate lines of inquiry, and giving a reference point for researchers and industrial developers in the field of biohydrogen production.

A review of microalgae biofilm as an eco-friendly approach to bioplastics, promoting environmental sustainability

In this comprehensive review, we delve into the challenges hindering the large-scale production of microalgae-based bioplastics, primarily focusing on economic feasibility and bioplastic quality. To address these issues, we explore the potential of microalgae biofilm cultivation as a sustainable and highly viable approach for bioplastic production. We present a proposed method for producing bioplastics using microalgae biofilm and evaluate its environmental impact using various tools such as life cycle analysis (LCA), ecological footprint analysis, resource flow analysis, and resource accounting. While pilot-scale and large-scale LCA data are limited, we utilize alternative indicators such as energy efficiency, carbon footprint, materials management, and community acceptance to predict the environmental implications of commercializing microalgae biofilm-based bioplastics. The findings of this study indicate that utilizing microalgae biofilm for bioplastic production offers significant environmental sustainability benefits. The system exhibits low energy requirements and a minimal carbon footprint. Moreover, it has the potential to address the issue of wastewater by utilizing it as a carbon source, thereby mitigating associated problems. However, it is important to acknowledge certain limitations associated with the method proposed in this review. Further research is needed to explore and engineer precise techniques for manipulating microalgae biofilm structure to optimize the accumulation of desired metabolites. This could involve employing chemical triggers, metabolic engineering, and genetic engineering to achieve the intended goals. In conclusion, this review highlights the potential of microalgae biofilm as a viable and sustainable solution for bioplastic production. While acknowledging the advantages, it also emphasizes the need for continued synthetic studies to enhance the efficiency and reliability of this approach. By addressing the identified drawbacks and maximizing the utilization of advanced techniques, we can further harness the potential of microalgae biofilm in contributing to a more environmentally friendly and economically feasible bioplastic industry.

Metabolic sink engineering in cyanobacteria: Perspectives and applications

Recent advances in metabolic engineering have made cyanobacteria emerge as promising and attractive microorganisms for sustainable production, by exploiting their natural capability for producing metabolites. The potential of metabolically engineered cyanobacterium would depend on its source-sink balance in the same way as other phototrophs. In cyanobacteria, the amount of light energy harvested (Source) is incompletely utilized by the cell to fix carbon (sink) resulting in wastage of the absorbed energy causing photoinhibition and cellular damage leading to lowered photosynthetic efficiency. Although regulatory pathways like photo-acclimation and photoprotective processes can be helpful unfortunately they limit the cell's metabolic capacity. This review describes approaches for source-sink balance and engineering heterologous metabolic sinks in cyanobacteria for enhanced photosynthetic efficiency. The advances for engineering additional metabolic pathways in cyanobacteria are also described which will provide a better understanding of the cyanobacterial source-sink balance and approaches for efficient cyanobacterial strains for valuable metabolites.

Laboratory- and Pilot-Scale Cultivation of Tetraselmis striata to Produce Valuable Metabolic Compounds

Marine microalgae are considered an important feedstock of multiple valuable metabolic compounds of high biotechnological potential. In this work, the marine microalga Tetraselmis striata was cultivated in different scaled photobioreactors (PBRs). Initially, experiments were performed using two different growth substrates (a modified F/2 and the commercial fertilizer Nutri-Leaf (30% TN-10% P-10% K)) to identify the most efficient and low-cost growth medium. These experiments took place in 4 L glass aquariums at the laboratory scale and in a 9 L vertical tubular pilot column. Enhanced biomass productivities (up to 83.2 mg L^-1 d^-1) and improved biomass composition (up to 41.8% d.w. proteins, 18.7% d.w. carbohydrates, 25.7% d.w. lipids and 4.2% d.w. total chlorophylls) were found when the fertilizer was used. Pilot-scale experiments were then performed using Nutri-Leaf as a growth medium in different PBRs: (a) a paddle wheel, open, raceway pond of 40 L, and (b) a disposable polyethylene (plastic) bag of 280 L working volume. Biomass growth and composition were also monitored at the pilot scale, showing that high-quality biomass can be produced, with important lipids (up to 27.6% d.w.), protein (up to 45.3% d.w.), carbohydrate (up to 15.5% d.w.) and pigment contents (up to 4.2% d.w. total chlorophylls), and high percentages of eicosapentaenoic acid (EPA). The research revealed that the strain successfully escalated in larger volumes and the biochemical composition of its biomass presents high commercial interest and could potentially be used as a feed ingredient.

Optimizing phosphorus removal for municipal wastewater post-treatment with Chlorella vulgaris

The microalgal species Chlorella vulgaris was cultivated in batch conditions to identify the optimum set of initial conditions for the best biomass growth rate, phosphate removal, polyphosphate accumulation, and protein productivity. To study the effect of phosphorus deficiency caused stress, the microalgal biomass was exposed to phosphorus deficiency conditions for periods varying between 1 and 10 days and inoculated at different initial biomass and phosphate concentrations. A 10-day period of phosphate deficiency, supported by low initial biomass concentration (∼0.25 mg DW L^-1), increased the phosphate removal by 62-175% when compared to the reference conditions. A 10-day period of biomass P-deficiency also boosted the polyphosphate accumulation and protein productivity, increasing them up to 40 and 46.8 times, respectively, if compared to reference conditions. At the same time, optimization algorithm model results suggested one-day biomass P-starvation with low initial biomass concentration as the optimum combination to achieve the highest performance while the initial phosphate concentration had less impact. The initial conditions suggested by the optimization model were validated in a sequencing batch photobioreactor, giving 101.7 and 138.0% more phosphate removal and polyphosphate accumulation, compared to the reference conditions. The obtained results present microalgae exposure to phosphorus stress as a supplementary tool for wastewater post-treatment targeted on rapid phosphorus removal.

Microalgal remediation and valorisation of polluted wastewaters for zero-carbon circular bioeconomy

Overexploitation of natural resources to meet human needs has considerably impacted CO₂ emissions, contributing to global warming and severe climatic change. This review furnishes an understanding of the sources, brutality, and effects of CO₂ emissions and compelling requirements for metamorphosis from a linear to a circular bioeconomy. A detailed emphasis on microalgae, its types, properties, and cultivation are explained with significance in attaining a zero-carbon circular bioeconomy. Microalgal treatment of a variety of wastewaters with the conversion of generated biomass into value-added products such as bio-energy and pharmaceuticals, along with agricultural products is elaborated. Challenges encountered in large-scale implementation of microalgal technologies for low-carbon circular bioeconomy are discussed along with solutions and future perceptions. Emphasis on the suitability of microalgae in wastewater treatment and its conversion into alternate low-carbon footprint bio-energies and value-added products enforcing a zero-carbon circular bioeconomy is the major focus of this review.

Optimization of CO2 Supply for the Intensive Cultivation of Chlorella sorokiniana IPPAS C-1 in the Laboratory and Pilot-Scale Flat-Panel Photobioreactors

Microalgae are increasingly being used for capturing carbon dioxide and converting it into valuable metabolites and biologically active compounds on an industrial scale. The efficient production of microalgae biomass requires the optimization of resources, including CO₂. Here, we estimated the productivity of Chlorella sorokiniana IPPAS C-1 depending on CO₂ concentrations and the ventilation coefficient of the gas-air mixture (GAM) in flat-panel photobioreactors (FP-PBRs) at laboratory (5 L) and pilot (18 L) scales. For the laboratory scale, the PBRs operated at 900 µmol quanta m⁻² s⁻¹ and 35.5 ± 0.5 °C; the optimal CO₂ flow rate was estimated at 3 mL CO₂ per 1 L of suspension per minute, which corresponds to 1.5% CO₂ in the GAM and an aeration rate of 0.2 vvm. These parameters, being scaled up within the pilot PBRs, resulted in a high specific growth rate (µ ≈ 0.1 h⁻¹) and high specific productivity (P_sp ≈ 1 g dw L⁻¹ d⁻¹). The principles of increasing the efficiency of the intensive cultivation of C. sorokiniana IPPAS C-1 are discussed. These principles are relevant for the development of technological regimes for the industrial production of Chlorella in flat-panel PBRs of various sizes.

Optimization of Microalgal Harvesting with Inorganic and Organic Flocculants Using Factorial Design of Experiments

Microalgae have a lot of potential as a source of several compounds of interest to various industries. However, developing a sustainable and efficient harvesting process on a large scale is still a major challenge. This is particularly a problem when the production of low-value products is intended. Chemical flocculation, followed by sedimentation, is seen as an alternative method to improve the energetic and economic balance of the harvesting step. In this study, inorganic (aluminum sulfate, ferric sulfate, ferric chloride) and organic (Zetag 8185, chitosan, Tanfloc SG) flocculants were tested to harvest Chlorella vulgaris in batch mode. Preliminary assays were conducted to determine the minimum dosages of each flocculant that generates primary flocs at different pH. Except for chitosan, the organic flocculants required small dosages to initiate floc formation. Additional studies were performed for the flocculants with a better performance in the preliminary assays. Zetag 8185 had the best results, reaching 98.8% and 97.9% efficiencies with dosages of 50 and 100 mg L−1, respectively. Lastly, a 24 full factorial design experiment was performed to determine the effects of the flocculant dosage, settling time, and mixing time on the Zetag 8185 harvesting efficiency. The harvesting efficiency of C. vulgaris was optimal at a dosage of 100 mg L−1 and 3 min of rapid mixing.