Metal-based flocculation to harvest microalgae: a look beyond separation efficiency

Integrating microalgae growth in biomethane plants: Process design, modelling, and cost evaluation

The integration of microalgae cultivation in anaerobic digestion (AD) plants can take advantage of relevant nutrients (ammonium and ortho-phosphate) and CO2 loads. The proposed scheme of microalgae integration in existing biogas plants aims at producing approximately 250 t·y-1 of microalgal biomass, targeting the biostimulants market that is currently under rapid expansion. A full-scale biorefinery was designed to treat 50 kt·y-1 of raw liquid digestate from AD and 0.45 kt·y-1 of CO2 from biogas upgrading, and 0.40 kt·y-1 of sugar-rich solid by-products from a local confectionery industry. An innovative three-stage cultivation process was designed, modelled, and verified, including: i) microalgae inoculation in tubular PBRs to select the desired algal strains, ii) microalgae cultivation in raceway ponds under greenhouses, and iii) heterotrophic microalgae cultivation in fermenters. A detailed economic assessment of the proposed biorefinery allowed to compute a biomass production cost of 2.8 ± 0.3 €·kg DW-1, that is compatible with current downstream process costs to produce biostimulants, suggesting that the proposed nutrient recovery route is feasible from the technical and economic perspective. Based on the case study analysis, a discussion of process, bioproducts and policy barriers that currently hinder the development of microalgae-based biorefineries is presented.

Recent advances in microalgal production, harvesting, prediction, optimization, and control strategies

The market value of microalgae has grown exponentially over the past two decades, due to their use in the pharmaceutical, nutraceutical, cosmetic, and aquatic/animal feed industries. In particular, high-value products such as omega-3 fatty acids, proteins, and pigments derived from microalgae have high demand. However, the supply of these high-value microalgal bioproducts is hampered by several critical factors, including low biomass and bioproduct yields, inefficiencies in monitoring microalgal growth, and costly harvesting methods. To overcome these constraints, strategies such as synthetic biology, bubble generation, photobioreactor designs, electro-/magnetic-/bioflocculation, and artificial intelligence integration in microalgal production are being explored. These strategies have significant promise in improving the production of microalgae, which will further boost market availability of algal-derived bioproducts. This review focuses on the recent advances in these technologies. Furthermore, this review aims to provide a critical analysis of the challenges in existing algae bioprocessing methods, and highlights future research directions.

Microalgae harvesting for wastewater treatment and resources recovery: A review

Microalgae-based wastewater treatment has been conceived to obtain reclaimed water and produce microalgal biomass for bio-based products and biofuels generation. However, microalgal biomass harvesting is challenging and expensive, hence one of the main bottlenecks for full-scale implementation. Finding an integrated approach that covers concepts of engineering, green chemistry and the application of microbial anabolism driven towards the harvesting processes, is mandatory for the widespread establishment of full-scale microalgae wastewater treatment plants. By using nature-based substances and applying concepts of chemical functionalization in already established harvesting methods, the costs of harvesting processes could be reduced while preventing microalgae biomass contamination. Moreover, microalgae produced during wastewater treatment have unique culture characteristics, such as the consortia, which are primarily composed of microalgae and bacteria, that should be accounted for prior to downstream processing. The aim of this review is to examine recent advances in microalgal biomass harvesting and recovery in wastewater treatment systems, considering the impact of consortia variability. The costs of available harvesting technologies, such as coagulation/flocculation, coupled to sedimentation and differential air flotation, are provided. Additionally, promising technologies are discussed, including autoflocculation, bioflocculation, new filtration materials, nanotechnology, microfluidic and magnetic methods.

Assessing the effect of multiple variables on the production of bioflocculant by Serratia marcescens: Flocculating activity, kinetics, toxicity, and flocculation mechanism

Bioflocculants gain attention as alternatives to chemical flocculants because they are more environmentally friendly and highly biodegradable. This study aims to improve the bioflocculant production by Serratia marcescens using one-variable-at-a-time (OVAT) analysis and analyze its flocculating activity performance, toxicity, and the flocculation mechanism. The effect of multiple variables including initial inoculum size, pH, mixing speed, temperature, growth medium, and incubation period was assessed through OVAT. Flocculating activity was then determined via jar test analysis, and toxicity test was performed using Daphnia magna and Daphnia pulex. The flocculation mechanism was determined via particle size distribution and zeta potential analysis. The optimum conditions for the improved bioflocculant production were as follows: 10% v/v initial inoculum size, pH 7, mixing speed of 150 rpm, room temperature, nutrient broth medium, and 72 h of incubation period. Scanning electron microscopy showed flake-like intact structure with coarse surface. The produced bioflocculant showed flocculating activity of 48% in 5227 ± 580 NTU initial kaolin turbidity with 1 mg/L concentration and 5% v/v dosage of bioflocculant, following the second-order kinetics. Toxicity test to D. magna and D. pulex showed the 48 h LC₅₀ values of 8.06 and 6.42 g/L, respectively; these values are greatly higher than the fabricated chemical flocculants. The flocculation process using bioflocculant produced by S. marcescens was suggested to occur via bridging mechanism because it greatly affected the particle size distribution. Results indicated that bioflocculant produced by S. marcescens is much environmentally friendly and has great potential for turbidity removal in water/wastewater.

Technoeconomic Evaluation of Microalgae Oil Production: Effect of Cell Disruption Method

Microalgae have a high capacity to capture CO2. Additionally, biomass contains lipids that can be used to produce biofuels, biolubricants, and other compounds of commercial interest. This study analyzed various scenarios for microalgae lipid production by simulation. These scenarios include cultivation in raceway ponds, primary harvest with three flocculants, secondary harvest with pressure filter (and drying if necessary), and three different technologies for the cell disruption step, which facilitates lipid extraction. The impact on energy consumption and production cost was analyzed. Both energy consumption and operating cost are higher in the scenarios that consider bead milling (8.79–8.88 kWh/kg and USD 41.06–41.41/kg), followed by those that consider high-pressure homogenization (HPH, 5.39–5.46 kWh/kg and USD 34.26–34.71/kg). For the scenarios that consider pressing, the energy consumption is 5.80–5.88 kWh/kg and the operating cost is USD 27.27–27.88/kg. The consumption of CO2 in scenarios that consider pressing have a greater capture (11.23 kg of CO2/kg of lipids). Meanwhile, scenarios that consider HPH are the lowest consumers of fresh water (5.3 m3 of water/kg of lipids). This study allowed us to develop a base of multiple comparative scenarios, evaluate different aspects involved in Chlorella vulgaris lipid production, and determine the impact of various technologies in the cell disruption stage.

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.

Piggery wastewater treatment with algae-bacteria consortia: Pilot-scale validation and techno-economic evaluation at farm level

The efficiency of an outdoor pilot-scale raceway pond treating the wastewaters generated by a large-scale piggery farm in Northern Italy was evaluated. The biomass productivity over 208 days of experimentation was 10.7 ± 6.5 g TSS·m^-2·d^-1, and ammoniacal nitrogen, orthophosphate, and COD average removal efficiencies were 90%, 90%, and 59%, respectively. Results were used to perform a comprehensive techno-economic analysis for integrating algae-based processes in farms of different sizes (100-10000 pigs). The amount of N disposed of on agricultural land could be reduced from 91% to 21%, increasing the fraction returned to the atmosphere from 2.4% to 63%, and the fraction in the biomass from 6.2% to 16%. For intensive farming, the release of 110 t N·ha^-1·y^-1 contained in the digestate could be avoided by including algae-bacteria processes. The biomass production cost was as low as 1.9 €·kg^-1, while the cost for nitrogen removal was 4.3 €·kg N^-1.

Respirometric assessment of bacterial kinetics in algae-bacteria and activated sludge processes

Algae-bacteria (AB) consortia can be exploited for effective wastewater treatment, based on photosynthetic oxygenation to reduce energy requirements for aeration. While algal kinetics have been extensively evaluated, bacterial kinetics in AB systems are still based on parameters taken from the activated sludge models, lacking an experimental validation for AB consortia. A respirometric procedure was therefore proposed, to estimate bacterial kinetics in both activated sludge and AB, under different conditions of temperature, pH, dissolved oxygen, and substrate availability. Bacterial activities were differently influenced by operational/environmental conditions, suggesting that the adoption of typical activated sludge parameters could be inadequate for AB modelling. Indeed, respirometric results show that bacteria in AB consortia were adapted to a wider range of conditions, compared to activated sludge, confirming that a dedicated calibration of bacterial kinetics is essential for effectively modelling AB systems, and respirometry was proven to be a powerful and reliable tool to this purpose.

The performance of co-immobilized strains isolated from activated sludge combined with Scenedesmus quadricauda to remove nutrients and organics in black odorous water

In this study, three bacteria were isolated from activated sludge (Pseudomonas aeruginosa, Bacillus subtilis, and Dietzia maris). After that, isolated strains and Scenedesmus quadricauda that could degrade refractory organics, as co-immobilization species, were prepared gel beads to treat black odorous water. Under the optimized conditions, the removal rate of chemical oxygen demand (COD), ammonia nitrogen (NH₃-N), total nitrogen (TN) and total phosphorus (TP) reached 94.36%, 95.7%, 91.22% and 95.27%, respectively, and organics (including aromatic proteins and microbial-by-product-like compounds) were also significantly removed. Microbial analysis reveals that the community structure had a significant difference before and after treatment, and the main dominant at the genus level was transformed from Nitrospirillum (approximately 18.03%) to Flavobacterium (approximately 17.64%). This study also found that the immobilized gel beads have excellent stability and reusability, which provided a feasible and robust bioremediation strategy for the treatment of actual black-odor water.

Assuaging Microalgal Harvesting Woes via Attached Growth: A Critical Review to Produce Sustainable Microalgal Feedstock

Third-generation biofuels that are derived from microalgal biomass have gained momentum as a way forward in the sustainable production of biodiesel. Such efforts are propelled by the intention to reduce our dependence on fossil fuels as the primary source of energy. Accordingly, growing microalgal biomass in the form of suspended cultivation has been a conventional technique for the past few decades. To overcome the inevitable harvesting shortcomings arising from the excessive energy and time needed to separate the planktonic microalgal cells from water medium, researchers have started to explore attached microalgal cultivation systems. This cultivation mode permits the ease of harvesting mature microalgal biomass, circumventing the need to employ complex harvesting techniques to single out the cells, and is economically attractive. However, the main bottleneck associated with attached microalgal growth is low biomass production due to the difficulties the microalgal cells have in forming attachment and populating thereafter. In this regard, the current review encompasses the novel techniques adopted to promote attached microalgal growth. The physicochemical effects such as the pH of the culture medium, hydrophobicity, as well as the substratum surface properties and abiotic factors that can determine the fate of exponential growth of attached microalgal cells, are critically reviewed. This review aims to unveil the benefits of an attached microalgal cultivation system as a promising harvesting technique to produce sustainable biodiesel for lasting applications.