Current Bottlenecks and Challenges of the Microalgal Biorefinery

Current progress and future perspective of microalgae biomass pretreatment using deep eutectic solvents

Pretreatment process is considered as the most important step for effective microalgae biomass refining and has gained more interest since last decades. However, the main obstacles to commercialize microalgae products are recalcitrant cell wall and lack of cost-effective, green, and sustainable pretreatment approaches. Till now, various microalgae pretreatment approaches have been applied prior to extraction steps to enhance the accessibility of solvent inside the cells. However, high energy consumption and the hazardousness of solvents are considerable problem for these pretreatment methods. In this regard, deep eutectic solvents are recognized as sustainable and green solvents possessing great potential for microalgae biomass processing due to their low toxicity, low cost, biodegradability, easy recycling, and reuse. This article provides the fundamentals of DES composition, synthesis, properties, and the current advances in the application of microalgae biomass process.

Application of microbial resources in biorefineries: Current trend and future prospects

The recent growing interest in sustainable and alternative sources of energy and bio-based products has driven the paradigm shift to an integrated model termed "biorefinery." Biorefinery framework implements the concepts of novel eco-technologies and eco-efficient processes for the sustainable production of energy and value-added biomolecules. The utilization of microbial resources for the production of various value-added products has been documented in the literatures. However, the appointment of these microbial resources in integrated resource management requires a better understanding of their status. The main of aim of this review is to provide an overview on the defined positioning and overall contribution of the microbial resources, i.e., algae, fungi and bacteria, for various bioprocesses and generation of multiple products from a single biorefinery. By utilizing waste material as a feedstock, biofuels can be generated by microalgae while sequestering environmental carbon and producing value added compounds as by-products. In parallel, fungal biorefineries are prolific producers of lignocellulose degrading enzymes along with pharmaceutically important novel products. Conversely, bacterial biorefineries emerge as a preferred platform for the transformation of standard cells into proficient bio-factories, developing chassis and turbo cells for enhanced target compound production. This comprehensive review is poised to offer an intricate exploration of the current trends, obstacles, and prospective pathways of microbial biorefineries, for the development of future biorefineries.

Melatonin, a phytohormone for enhancing the accumulation of high-value metabolites and stress tolerance in microalgae: Applications, mechanisms, and challenges

High-value metabolites, such as carotenoids, lipids, and proteins, are synthesized by microalgae and find applications in various fields, including food, health supplements, and cosmetics. However, the potential of the microalgal industry to serve these sectors is constrained by low productivity and high energy consumption. Environmental stressors can not only stimulate the accumulation of secondary metabolites in microalgae but also induce oxidative stress, suppressing cell growth and activity, thereby resulting in a decrease in overall productivity. Using melatonin (MT) under stressful conditions is an effective approach to enhance the productivity of microalgal metabolites. This review underscores the role of MT in promoting the accumulation of high-value metabolites and enhancing stress resistance in microalgae under stressful and wastewater conditions. It discusses the underlying mechanisms whereby MT enhances metabolite synthesis and improves stress resistance. The review also offers new perspectives on utilizing MT to improve microalgal productivity and stress resistance in challenging environments.

Microalgal lutein: Advancements in production, extraction, market potential, and applications

Lutein, a bioactive xanthophyll, has recently attracted significant attention for numerous health benefits, e.g., protection of eye health, macular degeneration, and acute and chronic syndromes etc. Microalgae have emerged as the best platform for high-value lutein production with high productivity, lutein content, and scale-up potential. Algal lutein possesses numerous bioactivities, hence widely used in pharmaceuticals, nutraceuticals, aquaculture, cosmetics, etc. This review highlights advances in upstream lutein production enhancement and feasible downstream extraction and cell disruption techniques for a large-scale lutein biorefinery. Besides bioprocess-related advances, possible solutions for existing production challenges in microalgae-based lutein biorefinery, market potential, and emerging commercial scopes of lutein and its potential health applications are also discussed. The key enzymes involved in the lutein biosynthesizing Methyl-Erythritol-phosphate (MEP) pathway have been briefly described. This review provides a comprehensive updates on lutein research advancements covering scalable upstream and downstream production strategies and potential applications for researchers and industrialists.

Production of chemicals and utilities in-house improves the environmental sustainability of phytoplankton-based biorefinery

Life cycle assessment was used to evaluate the environmental impacts of phytoplanktonic biofuels as possible sustainable alternatives to fossil fuels. Three scenarios were examined for converting planktonic biomass into higher-value commodities and energy streams using the alga Scenedesmus sp. and the cyanobacterium Arthrospira sp. as the species of interest. The first scenario (Sc-1) involved the production of biodiesel and glycerol from the planktonic biomass. In the second scenario (Sc-2), biodiesel and glycerol were generated from the planktonic biomass, and biogas was produced from the residual biomass. The process also involved using a catalyst derived from snail shells for biodiesel production. The third scenario (Sc-3) was similar to Sc-2 but converted CO2 from the biogas upgrading to methanol, which was then used in synthesizing biodiesel. The results indicated that Sc-2 and Sc-3 had a reduced potential (up to 60 % less) for damaging human health compared to Sc-1. Sc-2 and Sc-3 had up to 61 % less environmental impact than Sc-1. Sc-2 and Sc-3 reduced the total cumulative exergy demand by up to 44 % compared to Sc-1. In conclusion, producing chemicals and utilities within the biorefinery could significantly improve environmental sustainability, reduce waste, and diversify revenue streams.

Microalgae as tools for bio-circular-green economy: Zero-waste approaches for sustainable production and biorefineries of microalgal biomass

Microalgae are promising organisms that are rapidly gaining much attention due to their numerous advantages and applications, especially in biorefineries for various bioenergy and biochemicals. This review focuses on the microalgae contributions to Bio-Circular-Green (BCG) economy, in which zero-waste approaches for sustainable production and biorefineries of microalgal biomass are introduced and their possible integration is discussed. Firstly, overviews of wastewater upcycling and greenhouse gas capture by microalgae are given. Then, a variety of valuable products from microalgal biomass, e.g., pigments, vitamins, proteins/peptides, carbohydrates, lipids, polyunsaturated fatty acids, and exopolysaccharides, are summarized to emphasize their biorefinery potential. Techno-economic and environmental analyses have been used to evaluate sustainability of microalgal biomass production systems. Finally, key issues, future perspectives, and challenges for zero-waste microalgal biorefineries, e.g., cost-effective techniques and innovative integrations with other viable processes, are discussed. These strategies not only make microalgae-based industries commercially feasible and sustainable but also reduce environmental impacts.

Strategies and challenges to enhance commercial viability of algal biorefineries for biofuel production

The rise in energy consumption would quadruple in the coming century and the, existing energy resources might be insufficient to meet the demand of the growing population. An alternative and sustainable energy resource is therefore needed to address the fossil fuel deficiency. The utility of microalgae strains in the aspect of biorefinery has been in research for quite some time. Algal biorefinery is an alternate way of renewable energy however even after decades of research it still suffers from commercialization bottlenecks. The current manuscript reviews the scenarios where the innovation needs an ignition for its commercialization. This review discusses the prospects of up-scale cultivation, and harvesting algal biomass for biorefineries. It narrates algal biorefinery hurdles that can be solved using integrated technology approach, life cycle assessment and applications of nanotechnology. The review also sheds light upon the ties of algal biorefineries with its economic viability.

Development of sustainable downstream processing for nutritional oil production

Nutritional oils (mainly omega-3 fatty acids) are receiving increased attention as critical supplementary compounds for the improvement and maintenance of human health and wellbeing. However, the predominant sources of these oils have historically shown numerous limitations relating to desirability and sustainability; hence the crucial focus is now on developing smarter, greener, and more environmentally favourable alternatives. This study was undertaken to consider and assess the numerous prevailing and emerging techniques implicated across the stages of fatty acid downstream processing. A structured and critical comparison of the major classes of disruption methodology (physical, chemical, thermal, and biological) is presented, with discussion and consideration of the viability of new extraction techniques. Owing to a greater desire for sustainable industrial practices, and a desperate need to make nutritional oils more available; great emphasis has been placed on the discovery and adoption of highly sought-after 'green' alternatives, which demonstrate improved efficiency and reduced toxicity compared to conventional practices. Based on these findings, this review also advocates new forays into application of novel nanomaterials in fatty acid separation to improve the sustainability of nutritional oil downstream processing. In summary, this review provides a detailed overview of the current and developing landscape of nutritional oil; and concludes that adoption and refinement of these sustainable alternatives could promptly allow for development of a more complete 'green' process for nutritional oil extraction; allowing us to better meet worldwide needs without costing the environment.

Valorization of Phaeodactylum tricornutum for integrated preparation of diadinoxanthin and fucoxanthin

Integrated preparation of high-purity carotenoids from marine microalgae using green and efficient methods still faces enormous challenges. In this study, valorization of the economic Phaeodactylum tricornutum using integrated preparation of diadinoxanthin (Ddx) and fucoxanthin (Fx) was explored containing four steps including algae cultivation, solvent extraction, ODS open-column chromatography, and ethanol precipitation for the first time. Several essential key factors were optimized for simultaneously extracting Ddx and Fx from P. tricornutum. ODS open-column chromatography was used to isolate Ddx and Fx. Purification of Ddx and Fx was accomplished using ethanol precipitation. After optimization, the purity of Ddx and Fx was more than 95%, and the total recovery rates of Ddx and Fx were approximately 55% and 85%, respectively. The purified Ddx and Fx were identified as all-trans-diadinoxanthin and all-trans-fucoxanthin, respectively. The antioxidant capacity of the purified Ddx and Fx was assessed using two tests in vitro: DPPH and ABTS radical assays.

Integrating wind-driven agitating blade into a floating photobioreactor to enhance fluid mixing and microalgae growth

Aiming at optimizing the poor fluid mixing state in the traditional horizontal floating photobioreactors and reducing the high energy consumption and operational cost induced by electric-driven mixing, a novel floating photobioreactor with an embedded wind-driven agitating blade (WDAB-FPBR) was proposed in this study, which can effectively utilize both wind and wave energy for fluid mixing. The results show that the selected wind-driven agitating blade contributed to a decrement of 75.3% in mixing time and an increment of 87.5% in mass transfer coefficient, and meanwhile strengthened the fluid velocity along the light gradient. Owing to the enhanced fluid flow and mixing properties, an even distribution of algae cells was achieved in the WDAB floating photobioreactor, which resulted in an improvement of 140% in the photosynthesis efficiency of microalgae. From this, the biomass yield and carbon removal ratio showed an increment of 88.9% and 73.9%, respectively.

Bioprospecting for fungal enzymes for applications in microalgal biomass biorefineries

Microalgal biomass is a promising feedstock for biofuels, feed/food, and biomaterials. However, while production and commercialization of single-product commodities are still not economically viable, obtaining multiple products in a biomass biorefinery faces several techno-economic challenges. The aim of this study was to identify a suitable source of hydrolytic enzymes for algal biomass saccharification. Screening of twenty-six fungal isolates for secreted enzymes activity on Chlamydomonas reinhardtii biomass resulted in the identification of Aspergillus niger IB-34 as a candidate strain. Solid-state fermentation on wheat bran produced the most active enzyme preparations. From sixty-five proteins identified by liquid chromatography coupled to mass spectrometry (LC-MS) (ProteomeXchange, identifier PXD034998) from A. niger IB-34, the majority corresponded to predicted secreted proteins belonging to the Gene Ontology categories of catalytic activity/hydrolase activity on glycosyl and O-glycosyl compounds. Skimmed biomass of biotechnologically relevant strains towards the production of commodities, Chlorella sorokiniana and Scenedesmus obliquus, was fully saccharified after a mild pretreatment at 80 °C for 10 min, at a high biomass load of 10% (w/v). The soluble liquid stream, after skimming and saccharification of biomass of both strains, was further converted into ethanol by fermentation with Saccharomyces cerevisiae at a theoretical maximum efficiency, in a separated saccharification and fermentation assays. The resulting insoluble protein, after biomass skimming with an organic solvent and enzymatic saccharification, was highly digestible in an in vitro digestion assay. Proof of concept is presented for an enzyme-assisted biomass biorefinery recovering 81% of the main biomass fractions in a likely suitable form for the conversion of lipids and carbohydrates into biofuels and proteins into feed/food. KEY POINTS: • Twenty-six fungal extracts were analyzed for saccharification of microalgal biomass. • Skimmed biomass was fully enzymatically saccharified and fermented into ethanol. • Up to 81% recovery of biomass fractions suitable for biofuels and feed/food.

Chlamydomonas reinhardtii: A Factory of Nutraceutical and Food Supplements for Human Health

Chlamydomonas reinhardtii (C. reinhardtii) is one of the most well-studied microalgae organisms that revealed important information for the photosynthetic and metabolic processes of plants and eukaryotes. Numerous extensive studies have also underpinned its great potential as a biochemical factory, capable of producing various highly desired molecules with a direct impact on human health and longevity. Polysaccharides, lipids, functional proteins, pigments, hormones, vaccines, and antibodies are among the valuable biomolecules that are produced spontaneously or under well-defined conditions by C. reinhardtii and can be directly linked to human nutrition and diet. The aim of this review is to highlight the recent advances in the field focusing on the most relevant applications related to the production of important biomolecules for human health that are also linked with human nutrition and diet. The limitations and challenges are critically discussed along with the potential future applications of C. reinhardtii biomass and processed products in the field of nutraceuticals and food supplements. The increasing need for high-value and low-cost biomolecules produced in an environmentally and economy sustainable manner also underline the important role of C. reinhardtii.

Microalgae Commercialization Using Renewable Lignocellulose Is Economically and Environmentally Viable

Conventional phototrophic cultivation for microalgae production suffers from low and unstable biomass productivity due to limited and unreliable light transmission outdoors. Alternatively, the use of a renewable lignocellulose-derived carbon source, cellulosic hydrolysate, offers a cost-effective and sustainable pathway to cultivate microalgae heterotrophically with high algal growth rate and terminal density. In this study, we evaluate the feasibility of cellulosic hydrolysate-mediated heterotrophic cultivation (Cel-HC) for microalgae production by performing economic and environmental comparisons with phototrophic cultivation through techno-economic analysis and life cycle assessment. We estimate a minimum selling price (MSP) of 4722 USD/t for producing high-purity microalgae through Cel-HC considering annual biomass productivity of 300 t (dry weight), which is competitive with the conventional phototrophic raceway pond system. Revenues from the lignocellulose-derived co-products, xylose and fulvic acid fertilizer, could further reduce the MSP to 2976 USD/t, highlighting the advantages of simultaneously producing high-value products and biofuels in an integrated biorefinery scheme. Further, Cel-HC exhibits lower environmental impacts, such as cumulative energy demand and greenhouse gas emissions, than phototrophic systems, revealing its potential to reduce the carbon intensity of algae-derived commodities. Our results demonstrate the economic and environmental competitiveness of heterotrophic microalgae production based on renewable bio-feedstock of lignocellulose.

Microalgae as Raw Materials for Aquafeeds: Growth Kinetics and Improvement Strategies of Polyunsaturated Fatty Acids Production

Studies have shown that ancient cultures used microalgae as food for centuries. Currently, scientific reports highlight the value of nutritional composition of microalgae and their ability to accumulate polyunsaturated fatty acids at certain operational conditions. These characteristics are gaining increasing interest for the aquaculture industry which is searching for cost-effective replacements for fish meal and oil because these commodities are one of the most significant operational expenses and their dependency has become a bottleneck for their sustainable development of the aquaculture industry. This review is aimed at highlighting the use of microalgae as polyunsaturated fatty acid source in aquaculture feed formulations, despite their scarce production at industrial scale. Moreover, this document includes several approaches to improve microalgae production and to increase the content of polyunsaturated fatty acids with emphasis in the accumulation of DHA, EPA, and ARA. Furthermore, the document compiles several studies which prove microalgae-based aquafeeds for marine and freshwater species. Finally, the study explores the aspects that intervene in production kinetics and improvement strategies with possibilities for upscaling and facing main challenges of using microalgae in the commercial production of aquafeeds.

Isolation, Characterization and Immunomodulatory Activity Evaluation of Chrysolaminarin from the Filamentous Microalga Tribonema aequale

The aim of this study is to investigate the differences in the accumulation capacity of chrysolaminarin among six Tribonema species and to isolate this polysaccharide for immunomodulatory activity evaluation. The results showed that T. aequale was the most productive strain with the highest content and productivity of chrysolaminarin, which were 17.20% (% of dry weight) and 50.91 mg/L/d, respectively. Chrysolaminarin was then extracted and isolated from this alga, and its monosaccharide composition was mainly composed of a glucose (61.39%), linked by β-D-(1→3) (main chain) and β-D-(1→6) (branch chain) glycosidic bonds, with a molecular weight of less than 6 kDa. In vitro immunomodulatory assays showed that it could activate RAW264.7 cells at a certain concentration (1000 μg/mL), as evidenced by the increased phagocytic activity and upregulated mRNA expression levels of IL-1β, IL6, TNF-α and Nos2. Moreover, Western blot revealed that this polysaccharide stimulated the phosphorylation of p-65, p-38 and JNK in NF-κB and MAPK signaling pathways. Overall, these findings provide a reference for the further development and utilization of algae-based chrysolaminarin, while also offering an in-depth understanding of the immunoregulatory mechanism.

A smart and precise mixing strategy for efficient and cost-effective microalgae production in open ponds

Microalgae biotechnology is a great candidate for carbon neutralization, wastewater treatment and the sustainable production of biofuels and food. Efficient and cost-effective microalgae production depends on highly coordinating the resources used for algal growth. However, dynamic natural disturbances such as culture temperature and sunlight can lead to the poor coordination and waste of resources. Open ponds are the most commonly used commercial microalgal production systems, and enhanced mixing can significantly increase their productivity, but mixing energy can be seriously wasted due to dynamic disturbances, presenting a hindrance to further reducing production costs. Herein, a smart and precise mixing strategy was developed for open ponds in which a paddle wheel's stirring speed for an open pond was smartly and precisely controlled in real time based on dynamic variations in light intensity and culture temperature. The proposed technology achieved the same biomass productivity of Spirulina platensis (8.37 g m^-2 day^-1) as a control with a constant high mixing rate under dynamic disturbances while reducing mixing energy inputs by approximately 30 % compared to the control. This study provides a promising method to address serious resource waste and poor coordination due to dynamic natural disturbances, holding great potential for efficient and cost-effective microalgae production.

Enhanced sustainable integration of CO2 utilization and wastewater treatment using microalgae in circular economy concept

Microalgae have been shown to have a promising potential for CO₂ utilization and wastewater treatment which still faces the challenges of high resource and energy requirements. The implementation of the circular economy concept is able to address the issues that limit the application of microalgae-based technologies. In this review, a comprehensive discussion on microalgae-based CO₂ utilization and wastewater treatment was provided, and the integration of this technology with the circular economy concept, for long-term economic and environmental benefits, was described. Furthermore, technological challenges and feasible strategies towards the improvement of microalgae cultivation were discussed. Finally, necessary regulations and effective policies favoring the implementation of microalgae cultivation into the circular economy were proposed. These are discussed to support sustainable development of microalgae-based bioremediation and bioproduction. This work provides new insights into the implementation of the circular economy concept into microalgae-based CO₂ utilization and wastewater treatment to enhance sustainable production.

A review on unit operations, challenges, opportunities, and strategies to improve algal based biodiesel and biorefinery

Globally, the demand for energy is increasing with an emphasis on green fuels for a sustainable future. As the urge for alternative fuels is accelerating, microalgae have emerged as a promising source that can not only produce high lipid but many other platform chemicals. Moreover, it is a better alternative in comparison to conventional feedstock due to yearlong easy and mass cultivation, carbon fixation, and value-added products extraction. To date, numerous studies have been done to elucidate these organisms for large-scale fuel production. However, enhancing the lipid synthesis rate and reducing the production cost still remain a major bottleneck for its economic viability. Therefore, this study compiles information on algae-based biodiesel production with an emphasis on its unit operations from strain selection to biofuel production. Additionally, strategies to enhance lipid accumulation by incorporating genetic, and metabolic engineering and the use of leftover biomass for harnessing bio-products have been discussed. Besides, implementing a biorefinery for extracting oil followed by utilizing leftover biomass to generate value-added products such as nanoparticles, biofertilizers, biochar, and biopharmaceuticals has also been discussed.

The Biorefinery of the Marine Microalga Crypthecodinium cohnii as a Strategy to Valorize Microalgal Oil Fractions

Chrypthecodinium cohnii lipids have been almost exclusively used as a source of Docosahexaenoic acid (DHA). Such an approach wastes the remaining microalgal lipid fraction. The present work presents a novel process to produce C. cohnii biomass, using low-cost industrial by-products (raw glycerol and corn steep liquor), in a 7L-bioreactor, under fed-batch regime. At the end of the fermentation, the biomass concentration reached 9.2 g/L and the lipid content and lipid average productivity attained 28.0% (w/w dry cell weight) and 13.6 mg/L h, respectively. Afterwards the microalgal biomass underwent a saponification reaction to produce fatty acid (FA) soaps, which were further converted into FA ethyl ester (FA EE). C. cohnii FA EE mixture was then fractionated, using the urea complexation method at different temperatures, in order to obtain a polyunsaturated fatty acid ethyl ester (PUFA EE) rich fraction, that could be used for food/pharmaceutical/cosmetic purposes, and a saturated fatty acid ethyl ester (SAT EE) rich fraction, which could be used as biodiesel. The temperature that promoted the best separation between PUFA and SAT EE, was −18 °C, resulting in a liquid fraction with 91.6% (w/w) DHA, and a solid phase with 88.2% of SAT and monounsaturated fatty acid ethyl ester (MONOUNSAT), which could be used for biodiesel purposes after a hydrogenation step.

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.

Mild acoustic processing of Tisochrysis lutea for multiproduct biorefineries

Cellular agriculture could represent a more sustainable alternative to current food and nutraceutical production processes. Tisochrysis lutea microalgae represents a rich source of antioxidants and omega-3 fatty acids essential for human health. However, current downstream technologies are limiting its use. The present work investigates mild targeted acoustic treatment of Tisochrysis lutea biomass at different growth stages and acoustic frequencies, intensities and treatment times. Significant differences have been observed in terms of the impact of these variables on the cell disruption and energy requirements. Lower frequencies of 20 kHz required a minimum of 4500 J to disrupt 90% of the cells, while only 1000 J at 1146 kHz. Comparing these results with current industry standards such as bead milling, up to six times less energy use has been identified. These mild biomass processing approaches offer a certain tunability which could suit a wide range of microorganisms with only minor adjustments.

Life cycle assessment of microalgal biorefinery: A state-of-the-art review

Microalgal biorefineries represent an opportunity to economically and environmentally justify the production of bioproducts. The generation of bioproducts within a biorefinery system must quantitatively demonstrate its viability in displacing traditional fossil-based refineries. To this end, several works have conducted life cycle analyses on microalgal biorefineries and have shown technological bottlenecks due to energy-intensive processes. This state-of-the-art review covers different studies that examined microalgal biorefineries through life cycle assessments and has identified strategic technologies for the sustainable production of microalgal biofuels through biorefineries. Different metrics were introduced to supplement life cycle assessment studies for the sustainable production of microalgal biofuel. Challenges in the comparison of various life cycle assessment studies were identified, and the future design choices for microalgal biorefineries were established.

Biosynthesis of microalgal lipids, proteins, lutein, and carbohydrates using fish farming wastewater and forest biomass under photoautotrophic and heterotrophic cultivation

Biorefineries enable the circular, sustainable, and economic use of waste resources if value-added products can be recovered from all the generated fractions at a large-scale. In the present studies the comparison and assessment for the production of value-added compounds (e.g., proteins, lutein, and lipids) by the microalga Chlorella sorokiniana grown under photoautotrophic or heterotrophic conditions was performed. Photoautotrophic cultivation generated little biomass and lipids, but abundant proteins (416.66 mg/g_CDW) and lutein (6.40 mg/g_CDW). Heterotrophic conditions using spruce hydrolysate as a carbon source favored biomass (8.71 g/L at C/N 20 and 8.28 g/L at C/N 60) and lipid synthesis (2.79 g/L at C/N 20 and 3.61 g/L at C/N 60) after 72 h of cultivation. Therefore, heterotrophic cultivation of microalgae using spruce hydrolysate instead of glucose offers a suitable biorefinery concept at large-scale for biodiesel-grade lipids production, whereas photoautotrophic bioreactors are recommended for sustainable protein and lutein biosynthesis.

Functional proteins through green refining of seafood side streams

Scarcity of nutritive protein is a major global problem, the severity of which is bound to increase with the rising population. The situation demands finding additional sources of proteins that can be both safe as well as acceptable to the consumer. Food waste, particularly from seafood is a plausible feedstock of proteins in this respect. Fishing operations result in appreciable amounts of bycatch having poor food value. In addition, commercial processing results in 50 to 60% of seafood as discards, which consist of shell, head, fileting frames, bones, viscera, fin, skin, roe, and others. Furthermore, voluminous amounts of protein-rich effluents are released during commercial seafood processing. While meat from the bycatch can be raw material for proteinous edible products, proteins from the process discards and effluents can be recovered through biorefining employing upcoming, environmental-friendly, low-cost green processes. Microbial or enzyme treatments release proteins bound to the seafood matrices. Physico-chemical processes such as ultrasound, pulse electric field, high hydrostatic pressure, green solvent extractions and others are available to recover proteins from the by-products. Cultivation of photosynthetic microalgae in nutrient media consisting of seafood side streams generates algal cell mass, a rich source of functional proteins. A zero-waste marine bio-refinery approach can help almost total recovery of proteins and other ingredients from the seafood side streams. The recovered proteins can have high nutritive value and valuable applications as nutraceuticals and food additives.

High-Purity Fucoxanthin Can Be Efficiently Prepared from Isochrysis zhangjiangensis by Ethanol-Based Green Method Coupled with Octadecylsilyl (ODS) Column Chromatography

The exploitation of new economically valuable microalgae as a sustainable source of minor high-value products can effectively promote the full utilization of microalgae. The efficient preparation of minor products from microalgae remains the challenge, owing to the coexistence of various components with a similar polarity in the microalgae biomass. In this study, a novel approach based on the sustainable-oriented strategy for fucoxanthin (FX) production was proposed, which consisted of four steps, including the culture of microalga, ethanol extraction, ODS column chromatography, and ethanol precipitation. The high-purity FX (around 95%) was efficiently obtained in a total recovery efficiency of 84.28 ± 2.56%. This study reveals that I. zhangjiangensis is a potentially promising feedstock for FX production and firstly provides a potentially eco-friendly method for the scale-up preparation of FX from the microalga I. zhangjiangensis.

Total Phenolic Content, Biomass Composition, and Antioxidant Activity of Selected Marine Microalgal Species with Potential as Aquaculture Feed

There has been growing interest in microalgal biomolecules for health and cosmetics, as well as in the use of microalgae as aquaculture feed due to the need to replace fishmeal and fish oil with sustainable yet equally nutritious alternatives. Aim of this study is to evaluate the potential of five marine microalgal species, namely Chlorella minutissima, Dunaliella salina, Isochrysis galbana, Nannochloropsis oculata and Tisochrysis lutea, for the co-production of antioxidants and aquaculture feed. Batch cultivation was performed under saturating light intensity and continuous aeration. Freeze-dried biomass was extracted sequentially with water and methanol and evaluated for phenolic content and antioxidant activity, as well as proximate composition and fatty acid profile. Methanolic extracts of C. minutissima presented the highest phenolic content, measured with the Folin–Ciocalteu assay, and antioxidant activity. However, HPLC and LC-MS showed the presence of non-pigment compounds only in T. lutea. Total phenolic content and antioxidant activity were correlated to chlorophyll content. N. oculata and T. lutea were rich in eicosapentaenoic acid and docosahexaenoic acid, respectively, as well as in protein. In conclusion, N. oculata and T. lutea are suitable candidates for further optimization, while the data presented suggest that pigment effects on the Folin–Ciocalteu method require reconsideration.

Rhodopseudomonas palustris: A biotechnology chassis

Rhodopseudomonas palustris is an attractive option for biotechnical applications and industrial engineering due to its metabolic versatility and its ability to catabolize a wide variety of feedstocks and convert them to several high-value products. Given its adaptable metabolism, R. palustris has been studied and applied in an extensive variety of applications such as examining metabolic tradeoffs for environmental perturbations, biodegradation of aromatic compounds, environmental remediation, biofuel production, agricultural biostimulation, and bioelectricity production. This review provides a holistic summary of the commercial applications for R. palustris as a biotechnology chassis and suggests future perspectives for research and engineering.

Paixão S, S. Fernandes A, C. Roseiro J, Alves L. New Insights on Carotenoid Production by Gordonia alkanivorans Strain 1B

Gordonia alkanivorans strain 1B is a desulfurizing bacterium and a hyper-pigment producer. Most carotenoid optimization studies have been performed with light, but little is still known on how carbon/sulfur-source concentrations influence carotenoid production under darkness. In this work, a surface response methodology based on a two-factor Doehlert distribution (% glucose in a glucose/fructose 10 g/L mixture; sulfate concentration) was used to study carotenoid and biomass production without light. These responses were then compared to those previously obtained under light. Moreover, carbon consumption was also monitored, and different metabolic parameters were further calculated. The results indicate that both light and glucose promote slower growth rates, but stimulate carotenoid production and carbon conversion to carotenoids and biomass. Fructose induces higher growth rates, and greater biomass production at 72 h; however, its presence seems to inhibit carotenoid production. Moreover, although at a much lower yield than under light, results demonstrate that under darkness the highest carotenoid production can be achieved with 100% glucose (10 g/L), ≥27 mg/L sulfate, and high growth time (>216 h). These results give a novel insight into the metabolism of strain 1B, highlighting the importance of culture conditions optimization to increase the process efficiency for carotenoid and/or biomass production.

Integrated marine microalgae biorefineries for improved bioactive compounds: A review

Marine microalgae offer a promising feedstock for biofuels and other valuable compounds for biorefining and carry immense potential to contribute to a clean energy and environment future. However, it is currently not economically feasible to use marine algae to produce biofuels, and the potential bioactive chemicals account for only a small market share. The production of algal biomass with multiple valuable chemicals is closely related to the algal species, cultivation conditions, culture systems, and production modes. Thus, higher requirements for screening of dominant algal strains, developing integrated technologies with the optimum culture conditions, efficient cultivation systems, and production modes to exploit algal biomass for biorefinery applications, are all needed. This review summarizes the screening of dominant microalgae, discusses the environmental conditions that may affect the growth, as well as the culture systems and production modes, and further emphasizes the valorization options of the algal biomass, which should help to offer a sustainable approach to run a profitable marine algae production system.

Cyanobacterial biorefinery: Towards economic feasibility through the maximum valorization of biomass

Cyanobacteria are well known for their plethora of applications in the fields of food industry, pharmaceuticals and bioenergy. Their simple growth requirements, remarkable growth rate and the ability to produce a wide range of bio-active compounds enable them to act as an efficient biorefinery for the production of valuable metabolites. Most of the cyanobacteria based biorefineries are targeting single products and thus fails to meet the efficient valorization of biomass. On the other hand, multiple products recovering cyanobacterial biorefineries can efficiently valorize the biomass with minimum to zero waste generation. But there are plenty of bottlenecks and challenges allied with cyanobacterial biorefineries. Most of them are being associated with the production processes and downstream strategies, which are difficult to manage economically. There is a need to propose new solutions to eliminate these tailbacks so on to elevate the cyanobacterial biorefinery to be an economically feasible, minimum waste generating multiproduct biorefinery. Cost-effective approaches implemented from production to downstream processing without affecting the quality of products will be beneficial for attaining economic viability. The integrated approaches in cultivation systems as well as downstream processing, by simplifying individual processes to unit operation systems can obviously increase the economic feasibility to a certain extent. Low cost approaches for biomass production, multiparameter optimization and successive sequential retrieval of multiple value-added products according to their high to low market value from a biorefinery is possible. The nanotechnological approaches in cyanobacterial biorefineries make it one step closer to the goal. The current review gives an overview of strategies used for constructing self-sustainable- economically feasible- minimum waste generating; multiple products based cyanobacterial biorefineries by the efficient valorization of biomass. Also the possibility of uplifting new cyanobacterial strains for biorefineries is discussed.

Microalgal Biorefinery Concepts’ Developments for Biofuel and Bioproducts: Current Perspective and Bottlenecks

Microalgae have received much interest as a biofuel feedstock. However, the economic feasibility of biofuel production from microalgae does not satisfy capital investors. Apart from the biofuels, it is necessary to produce high-value co-products from microalgae fraction to satisfy the economic aspects of microalgae biorefinery. In addition, microalgae-based wastewater treatment is considered as an alternative for the conventional wastewater treatment in terms of energy consumption, which is suitable for microalgae biorefinery approaches. The energy consumption of a microalgae wastewater treatment system (0.2 kW/h/m³) was reduced 10 times when compared to the conventional wastewater treatment system (to 2 kW/h/m³). Microalgae are rich in various biomolecules such as carbohydrates, proteins, lipids, pigments, vitamins, and antioxidants; all these valuable products can be utilized by nutritional, pharmaceutical, and cosmetic industries. There are several bottlenecks associated with microalgae biorefinery. Hence, it is essential to promote the sustainability of microalgal biorefinery with innovative ideas to produce biofuel with high-value products. This review attempted to bring out the trends and promising solutions to realize microalgal production of multiple products at an industrial scale. New perspectives and current challenges are discussed for the development of algal biorefinery concepts.

Biodegradable Solvents: A Promising Tool to Recover Proteins from Microalgae

The world will face a significant protein demand in the next few decades, and due to the environmental concerns linked to animal protein, new sustainable protein sources must be found. In this regard, microalgae stand as an outstanding high-quality protein source. However, different steps are needed to separate the proteins from the microalgae biomass and other biocompounds. The protein recovery from the disrupted biomass is usually the bottleneck of the process, and it typically employs organic solvents or harsh conditions, which are both detrimental to protein stability and planet health. Different techniques and methods are applied for protein recovery from various matrices, such as precipitation, filtration, chromatography, electrophoresis, and solvent extraction. Those methods will be reviewed in this work, discussing their advantages, drawbacks, and applicability to the microalgae biorefinery process. Special attention will be paid to solvent extraction performed with ionic liquids (ILs) and deep eutectic solvents (DESs), which stand as promising solvents to perform efficient protein separations with reduced environmental costs compared to classical alternatives. Finally, several solvent recovery options will be analyzed to reuse the solvent employed and isolate the proteins from the solvent phase.

Microalgal metabolic engineering strategies for the production of fuels and chemicals

Microalgae are promising sustainable resources because of their ability to convert CO₂ into biofuels and chemicals directly. However, the industrial production and economic feasibility of microalgal bioproducts are still limited. As such, metabolic engineering approaches have been undertaken to enhance the productivities of microalgal bioproducts. In the last decade, impressive advances in microalgae metabolic engineering have been made by developing genetic engineering tools and multi-omics analysis. This review presents comprehensive microalgal metabolic pathways and metabolic engineering strategies for producing lipids, long chain-polyunsaturated fatty acids, terpenoids, and carotenoids. Additionally, promising metabolic engineering approaches specific to target products are summarized. Finally, this review discusses current challenges and provides future perspectives for the effective production of chemicals and fuels via microalgal metabolic engineering.

Production of microalgae with high lipid content and their potential as sources of nutraceuticals

In the current global scenario, the world is under a serious dilemma due to the increasing human population, industrialization, and urbanization. The ever-increasing need for fuels and increasing nutritional problems have made a serious concern on the demand for nutrients and renewable and eco-friendly fuel sources. Currently, the use of fossil fuels is creating ecological and economic problems. Microalgae have been considered as a promising candidate for high-value metabolites and alternative renewable energy sources. Microalgae offer several advantages such as rapid growth rate, efficient land utilization, carbon dioxide sequestration, ability to cultivate in wastewater, and most importantly, they do not participate in the food crop versus energy crop dilemma or debate. An efficient microalgal biorefinery system for the production of lipids and subsequent byproduct for nutraceutical applications could well satisfy the need. But, the current microalgal cultivation systems for the production of lipids and nutraceuticals do not offer techno-economic feasibility together with energy and environmental sustainability. This review article has its main focus on the production of lipids and nutraceuticals from microalgae, covering the current strategies used for lipid production and the major high-value metabolites from microalgae and their nutraceutical importance. This review also provides insights on the future strategies for enhanced microalgal lipid production and subsequent utilization of microalgal biomass.

GRAPHICAL ABSTRACT

Establishment of a simple method to evaluate mixing times in a plastic bag photobioreactor using image processing based on freeware tools

Objective

Accurate determination of the mixing time in bioreactors is essential for the optimization of the productivity of bioprocesses. The aim of this work was to develop a simple optical method to determine the mixing time in a photobioreactor. The image processing method should be based on freeware tools, should not require programming skills, and thus could be used in education within high schools and in early stages of undergraduate programs.

Results

An optical method has been established to analyze images from recorded videos of mixing experiments. The steps are: 1. Extraction of a sequence of images from the video file; 2. Cropping of the pictures; 3. Background removal; and 4. Image analysis and mixing time evaluation based on quantification of pixel-to-pixel heterogeneity within a given area of interest. The novel method was generally able to track the dependency between aeration rate and mixing time within the investigated photobioreactor. In direct comparison, a pearson correlation coefficient of rho = 0.99 was obtained. Gas flow rates between 10 L h⁻¹, and 300 L h⁻¹ resulted from mixing times of between 48 and 14 s, respectively. This technique is applicable without programming skills and can be used in education with inexperienced user groups.

Wastewater-based microalgal biorefineries for the production of astaxanthin and co-products: Current status, challenges and future perspectives

The freshwater microalgae Haematococcus pluvialis and Chlorella zofingiensis are attractive biorefinery feedstocks in view of their ability to simultaneously synthesize astaxanthin and other valuable metabolites. Nonetheless, there are concerns regarding the sustainability of such biorefineries due to the high freshwater footprint of microalgae cultivation. The integration of wastewater as an alternative growth media is a promising approach to reduce freshwater demand. Wastewater-based cultivation enables the recovery of essential nutrients required for microalgae growth and consequently results in phycoremediation of wastewater, thus promoting the concept of a circular economy and further enhancing the sustainability of the process. In this review, recent developments in wastewater-integrated cultivation of H. pluvialis and C. zofingiensis for astaxanthin production are discussed. Furthermore, prospective strategies for overcoming the inherent challenges of wastewater-based cultivation are reviewed. Moreover, the biorefinery potential of wastewater-grown H. pluvialis and C. zofingiensis is delineated and future perspectives of wastewater-based biorefineries are outlined.

Comparative life cycle assessment of a mesh ultra-thin layer photobioreactor and a tubular glass photobioreactor for the production of bioactive algae extracts

This study aimed at the comparison of two different photobioreactors with focus on technology and sustainability. The mesh ultra-thin layer photobioreactor (MUTL-PBR) exhibited around 3-fold biomass based space-time-yield and an around 10-fold specific antioxidant capacity than the traditional reference photobioreactor. Life cycle assessment (LCA) was done under autotrophic conditions in both pilot scale reactors with focus on biomass production and on antioxidant capacity of the biomass, respectively. Biomass production within the reference reactor showed a lower environmental impact in most categories. A significantly higher energy demand for mixing and cooling of the cell suspension within the MUTL-PBR is the major reason for its environmental burden. This relates to high impacts in the categories "non-renewable energy" and "global warming potential" per kg biomass. Comparing algal antioxidant capacity, environmental impact of the MUTL cultivation was 5-10 times lower. This clearly illustrates the potential of MUTL-PBR for sustainable production of bioactive substances.

Microalgae as Sustainable Biofactories to Produce High-Value Lipids: Biodiversity, Exploitation, and Biotechnological Applications

Microalgae are often called “sustainable biofactories” due to their dual potential to mitigate atmospheric carbon dioxide and produce a great diversity of high-value compounds. Nevertheless, the successful exploitation of microalgae as biofactories for industrial scale is dependent on choosing the right microalga and optimum growth conditions. Due to the rich biodiversity of microalgae, a screening pipeline should be developed to perform microalgal strain selection exploring their growth, robustness, and metabolite production. Current prospects in microalgal biotechnology are turning their focus to high-value lipids for pharmaceutic, nutraceutic, and cosmetic products. Within microalgal lipid fraction, polyunsaturated fatty acids and carotenoids are broadly recognized for their vital functions in human organisms. Microalgal-derived phytosterols are still an underexploited lipid resource despite presenting promising biological activities, including neuroprotective, anti-inflammatory, anti-cancer, neuromodulatory, immunomodulatory, and apoptosis inductive effects. To modulate microalgal biochemical composition, according to the intended field of application, it is important to know the contribution of each cultivation factor, or their combined effects, for the wanted product accumulation. Microalgae have a vital role to play in future low-carbon economy. Since microalgal biodiesel is still costly, it is desirable to explore the potential of oleaginous species for its high-value lipids which present great global market prospects.

Marine bioactives: from energy to nutrition

Microalgae have been evaluated as promising resource for biodiesel production, but algal biofuel production is not yet commercially viable, which reflects the high energy costs linked with cultivation, harvesting, and dewatering of algae. As crude oil processing declines, microalgae biorefineries are being considered for producing bioactives such as enzymes, proteins, omega-3 oils, pigments, recombinant products, and vitamins, to offset the costs of biofuel production. We believe that producing algal bioactives through advanced manufacturing pathways, encompassing a biorefinery approach, would be effective, profitable, and economical.

Rapid analytical methods for the microalgal and cyanobacterial biorefinery: Application on strains of industrial importance

To realize the potential of microalgae in the biorefinery context, exploitation of multiple products is necessary for profitability and bioproduct valorization. Appropriate analytical tools are required for growth optimization, culture monitoring, and quality control purposes, with safe, low-tech, and low-cost solutions favorable. Rapid, high-throughput, and user-friendly methodologies were devised for (a) determination of phycobiliproteins, chlorophylls, carotenoids, proteins, carbohydrates, and lipids and (b) qualitative and quantitative carotenoid profiling using UPLC-PDA-MS^E . The complementary methods were applied on 11 commercially important microalgal strains including prasinophytes, haptophytes, and cyanobacteria, highlighting the suitability of some strains for coproduct exploitation and the method utility for research and industrial biotechnology applications. The UPLC method allowed separation of 41 different carotenoid compounds in <15 min. Simple techniques are described for further quantification and comparison of pigment profiles, allowing for easy strain selection and optimization for pigment production, with suitability for biotechnological or biomedical applications.