Scale-Up of flat plate photobioreactors considering diffuse and direct light characteristics

This study investigates the scaling of photobioreactor productivity based on the growth of Nannochloropsis salina incorporating the effects of direct and diffuse light. The scaling and optimization of photobioreactor geometry was analyzed by determining the growth response of a small-scale system designed to represent a core sample of a large-scale photobioreactor. The small-scale test apparatus was operated at a variety of light intensities on a batch time scale to generate a photosynthetic irradiance (PI) growth dataset, ultimately used to inform a PI growth model. The validation of the scalability of the PI growth model to predict productivity in large-scale systems was done by comparison with experimental growth data collected from two geometrically different large-scale photobioreactors operated at a variety of light intensities. For direct comparison, the small-scale and large-scale experimental systems presented were operated similarly and in such a way to incorporate cultivation relevant time scales, light intensities, mixing, and nutrient loads. Validation of the scalability of the PI growth model enables the critical evaluation of different photobioreactor geometries and design optimization incorporating growth effects from diffuse and direct light. Discussion focuses on the application of the PI growth model to assess the effect of diffuse light growth compared to direct light growth for the evaluation of photobioreactors followed by the use of the model for photobioreactor geometry optimization on the metric of areal productivity.     

Microalgae cultivation in air-lift reactors: modeling biomass yield and growth rate as a function of mixing frequency

The slow development of microalgal biotechnology stems from the failure in the design of large-scale photobioreactors where light energy is efficiently utilized. Due to the light gradient inside the reactor and depending on the mixing properties, algae are subjected to certain light/dark cycles where the light period is characterized by a light gradient. These light/dark cycles will determine productivity and biomass yield on light energy. Air-lift reactors can be used for microalgae cultivation and medium-frequency light/dark cycles will be found in these systems. Light/dark cycles are associated with two basic parameters: first, the light fraction, i.e., the ratio between the light period and the cycle time and second, the frequency of the light/dark cycle. In the present work, light/dark cycles found in air-lift reactors were simulated taking into account the light gradient during the light period. The effect of medium-frequency cycle time (10-100 s) and light fraction (0.1-1) on growth rate and biomass yield on light energy of the microalgae Dunaliella tertiolecta was studied. The biomass yield and growth rates were mainly affected by the light fraction, while cycle time had little influence. Response surface methodology was used and a statistical model describing the effect of light fraction and cycle time on growth rate and biomass yield on light energy was developed. The use of the model as a reactor design criterion is discussed.     

Photosynthetic efficiency of Chlorella sorokiniana in a turbulently mixed short light‐path photobioreactor

To be able to study the effect of mixing as well as any other parameter on productivity of algal cultures, we designed a lab‐scale photobioreactor in which a short light path (SLP) of (12 mm) is combined with controlled mixing and aeration. Mixing is provided by rotating an inner tube in the cylindrical cultivation vessel creating Taylor vortex flow and as such mixing can be uncoupled from aeration. Gas exchange is monitored on‐line to gain insight in growth and productivity. The maximal productivity, hence photosynthetic efficiency, of Chlorella sorokiniana cultures at high light intensities (1,500 μmol m^?1 s^?1) was investigated in this Taylor vortex flow SLP photobioreactor. We performed duplicate batch experiments at three different mixing rates: 70, 110, and 140 rpm, all in the turbulent Taylor vortex flow regime. For the mixing rate of 140 rpm, we calculated a quantum requirement for oxygen evolution of 21.2 mol PAR photons per mol O₂ and a yield of biomass on light energy of 0.8 g biomass per mol PAR photons. The maximal photosynthetic efficiency was found at relatively low biomass densities (2.3 g L^?1) at which light was just attenuated before reaching the rear of the culture. When increasing the mixing rate twofold, we only found a small increase in productivity. On the basis of these results, we conclude that the maximal productivity and photosynthetic efficiency for C. sorokiniana can be found at that biomass concentration where no significant dark zone can develop and that the influence of mixing‐induced light/dark fluctuations is marginal. © 2010 American Institute of Chemical Engineers Biotechnol. Prog., 2010     

Efficiency of light utilization of Chlamydomonas reinhardtii under medium-duration light/dark cycles

The light regime inside a photobioreactor is characterized by a light gradient with full (sun)light at the light-exposed surface and darkness in the interior of the bioreactor. Consequently, depending on the mixing characteristics, algae will be exposed to certain light/dark cycles. In this study the green alga Chlamydomonas reinhardtii was cultivated under five different light regimes: (1) continuous illumination; (2) a square-wave light/dark cycle with a light fraction (epsilon) of 0.5 and a duration (t(c)) of 6.1 s; (3) epsilon=0.5, t(c)=14.5 s; (4) epsilon=0.5, t(c)=24.3 s and (5) epsilon=0.8, t(c)=15.2 s. The biomass yield on light energy, protein per photons, decreased under light/dark cycles (epsilon=0. 5) in comparison to continuous light (CL), from 0.207 (CL) to 0.117-0.153 g mol(-1) (epsilon=0.5). Concomitantly, the maximal specific photosynthetic activity, oxygen production per protein, decreased from 0.94 (CL) to 0.64-0.66 g g(-1) h(-1) (epsilon=0.5). Also the quantum yield of photochemistry, yield of the conversion of light energy into chemical energy, decreased from 0.47 (CL) to 0. 23 (epsilon=0.5, t(c)=24.3 s). Apparently, C. reinhardtii is not able to maintain a high photosynthetic capacity under medium-duration light/dark cycles and since specific light absorption did not change, light utilization efficiency decreased in comparison to continuous illumination.     

Photosynthetic efficiency of Chlamydomonas reinhardtii in flashing light

Efficient light to biomass conversion in photobioreactors is crucial for economically feasible microalgae production processes. It has been suggested that photosynthesis is enhanced in short light path photobioreactors by mixing‐induced flashing light regimes. In this study, photosynthetic efficiency and growth of the green microalga Chlamydomonas reinhardtii were measured using LED light to simulate light/dark cycles ranging from 5 to 100 Hz at a light‐dark ratio of 0.1 and a flash intensity of 1000 µmol m⁻² s⁻¹. Light flashing at 100 Hz yielded the same photosynthetic efficiency and specific growth rate as cultivation under continuous illumination with the same time‐averaged light intensity (i.e., 100 µmol m⁻² s⁻¹). The efficiency and growth rate decreased with decreasing flash frequency. Even at 5 Hz flashing, the rate of linear electron transport during the flash was still 2.5 times higher than during maximal growth under continuous light, suggesting storage of reducing equivalents during the flash which are available during the dark period. In this way the dark reaction of photosynthesis can continue during the dark time of a light/dark cycle. Understanding photosynthetic growth in dynamic light regimes is crucial for model development to predict microalgal photobioreactor productivities. Biotechnol. Bioeng. 2011;108: 2905–2913. © 2011 Wiley Periodicals, Inc.     

Turbulence in mass algal cultures and the role of light/dark fluctuations

In mass algal cultures, some form of agitation is usually provided; among other effects, this moves the organisms though an optically dense profile and provides mixing. During this transport, medium frequency fluctuations in the light energy supply are perceived by the algae, which are of the order of 1 Hz and less. It has been suggested that turbulence with the resultant light/dark cycles of medium frequency enhances productivity. However, turbulence has two major influences in a well mixed system: it facilitates fluctuating light regimes and increases the transfer rates between the growth medium and the cultured organism. An estimation of productivity as oxygen liberation was measured under laminar and turbulent flow rates, and varying light/dark ratios. Increased turbulence, which increased exchange rates of nutrients and metabolites between the cells and their growth medium, together with increased light/dark frequencies, increased productivity and photosynthetic efficiency.     

Photosynthetic efficiency of Chlamydomonas reinhardtii in attenuated, flashing light

As a result of mixing and light attenuation, algae in a photobioreactor (PBR) alternate between light and dark zones and, therefore, experience variations in photon flux density (PFD). These variations in PFD are called light/dark (L/D) cycles. The objective of this study was to determine how these L/D cycles affect biomass yield on light energy in microalgae cultivation. For our work, we used controlled, short light path, laboratory, turbidostat‐operated PBRs equipped with a LED light source for square‐wave L/D cycles with frequencies from 1 to 100 Hz. Biomass density was adjusted that the PFD leaving the PBR was equal to the compensation point of photosynthesis. Algae were acclimated to a sub‐saturating incident PFD of 220 µmol m^?2 s^?1 for continuous light. Using a duty cycle of 0.5, we observed that L/D cycles of 1 and 10 Hz resulted on average in a 10% lower biomass yield, but L/D cycles of 100 Hz resulted on average in a 35% higher biomass yield than the yield obtained in continuous light. Our results show that interaction of L/D cycle frequency, culture density and incident PFD play a role in overall PBR productivity. Hence, appropriate L/D cycle setting by mixing strategy appears as a possible way to reduce the effect that dark zone exposure impinges on biomass yield in microalgae cultivation. The results may find application in optimization of outdoor PBR design to maximize biomass yields. Biotechnol. Bioeng. 2012; 109: 2567–2574. © 2012 Wiley Periodicals, Inc.     

Photosynthetic efficiency and oxygen evolution of Chlamydomonas reinhardtii under continuous and flashing light

As a result of mixing and light attenuation in a photobioreactor (PBR), microalgae experience light/dark (L/D) cycles that can enhance PBR efficiency. One parameter which characterizes L/D cycles is the duty cycle; it determines the time fraction algae spend in the light. The objective of this study was to determine the influence of different duty cycles on oxygen yield on absorbed light energy and photosynthetic oxygen evolution. Net oxygen evolution of Chlamydomonas reinhardtii was measured for four duty cycles (0.05, 0.1, 0.2, and 0.5) in a biological oxygen monitor (BOM). Oversaturating light flashes were applied in a square-wave fashion with four flash frequencies (5, 10, 50, and 100 Hz). Algae were precultivated in a turbidostat and acclimated to a low photon flux density (PFD). A photosynthesis–irradiance (PI) curve was measured under continuous illumination and used to calculate the net oxygen yield, which was maximal between a PFD of 100 and 200 μmol m^?2?s^?1. Net oxygen yield under flashing light was duty cycle-dependent: the highest yield was observed at a duty cycle of 0.1 (i.e., time-averaged PFD of 115 μmol m^?2?s^?1). At lower duty cycles, maintenance respiration reduced net oxygen yield. At higher duty cycles, photon absorption rate exceeded the maximal photon utilization rate, and, as a result, surplus light energy was dissipated which led to a reduction in net oxygen yield. This behavior was identical with the observation under continuous light. Based on these data, the optimal balance between oxygen yield and production rate can be determined to maximize PBR productivity.     

Study of hydrodynamic characteristics in tubular photobioreactors

In this work, the hydrodynamic characteristics in tubular photobioreactors with a series of helical static mixers built-in were numerically investigated using computational fluid dynamics (CFD). The influences of height and screw pitch of the helical static mixer and fluid inlet velocity on the cell trajectories, swirl numbers and energy consumption were examined. In order to verify the actual results for cultivation of microalgae, cultivation experiments of freshwater Chlorella sp. were carried out in photobioreactor with and without helical static mixer built-in at the same time. It was shown that with built-in helical static mixer, the mixing of fluid could be intensified, and the light/dark cycle could also be achieved which is of benefit for the growth of microalgae. The biomass productivity of Chlorella sp. in tubular photobioreactor with helical static mixer built-in was 37.26 % higher than that in the photobioreactor without helical static mixer.     

The potential of quantitative models to improve microalgae photosynthetic efficiency

The massive increase in carbon dioxide concentration in the atmosphere driven by human activities is causing huge negative consequences and new sustainable sources of energy, food and materials are highly needed. Algae are unicellular photosynthetic microorganisms that can provide a highly strategic contribution to this challenge as alternative source of biomass to complement crops cultivation. Algae industrial cultures are commonly limited by light availability, and biomass accumulation is strongly dependent on their photon‐to‐biomass conversion efficiency. Investigation of algae photosynthetic metabolism is thus strategic for the generation of more efficient strains with higher productivity. Algae are cultivated at industrial scale in conditions highly different from the natural niches they adapted to and strains development efforts must fully consider the seminal influence on productivity of regulatory mechanism of photosynthesis as well as of cultivation parameters like cells concentration, light distribution in the culture, mixing, nutrients and carbon dioxide availability. In this review we will focus in particular on how mathematical models can account for the complex influence of all environmental parameters and can be exploited for development of improved algae strains.     

A novel photobioreactor with transparent rectangular chambers for cultivation of microalgae

An open tank photobioreactor containing transparent rectangular chambers (TRCs) was developed to improve the photosynthetic efficiency of microalgal cultivation. The TRCs, made of transparent acrylic, conducted light deep into the photobioreactor, especially at high cell concentrations. The average irradiance, I_av, was calculated by Lambert–Beer's law, and was used to determine the light conditions in the cultivation system. The photobioreactor provided large areas of illumination that improved the effective utilization of light energy for microalgae growth and created a good artificial environment for a high rate of cell growth, even at low I_av. The biomass concentration of Chlorella sp. reached 3.745 g L⁻¹ on the 13th day, with biomass productivity of 0.340 g L⁻¹ d⁻¹. The total biomass obtained was 56% more than that of similar culture systems without TRCs.     

Pilot-scale open-channel raceways and flat-panel photobioreactors maintain well-mixed conditions under a wide range of mixing energy inputs

Turbulent mixing in pilot-scale cultivation systems influences the productivity of photoautotrophic cultures. We studied turbulent mixing by applying particle image velocimetry and acoustic doppler velocimetry to pilot-scale, flat-panel photobioreactor, and open-channel raceway. Mixing energy inputs were varied from 0.1 to 2.1 W·m⁻³. The experimental results were used to quantify turbulence and to validate computational fluid dynamics models, from which Lagrangian representations of the fluid motion in these reactors were derived. The results of this investigation demonstrated that differences in mixing energy input do not significantly impact the structure of turbulence and the light/dark cycling frequencies experienced by photoautotrophic cells within the reactors. The experimental and computational results of our research demonstrated that well-mixed conditions exist in pilot-scale, flat-panel photobioreactors and open-channel raceways, even for relatively low mixing energy inputs.     

Energy-efficient cultivation of Chlamydomonas reinhardtii for lipid accumulation under flashing illumination conditions

Microalgal cultivation has been limited by the efficiency and costs associated with providing light energy, the most expensive and essential element needed for microalgal growth to a culture, particularly to cultures grown in a photo bioreactor (PBR). This study examined the economic benefits of using flashing illumination conditions in the context of microalgal cultivation. Chlamydomonas reinhardtii was cultivated under various conditions, including various inoculum sizes, light intensities, and durations of the light and dark periods. Our results showed that the highest microalgal growth efficiencies could be obtained using a large inoculum size under high intensity illumination accompanied by a 1:1 ratio of light and dark periods. The duration of the flashing light period was further optimized; permitting light energy savings of 62.5% of the light energy expended under continuous illumination conditions without reducing the biomass or lipid productivity. This study provides a more economical approach to cultivating C. reinhardtii via optimized flashing illumination without sacrificing microalgal growth or lipid content.     

Specific growth rate of Chlamydomonas reinhardtii and Chlorella sorokiniana under medium duration light/dark cycles: 13–87 s

The specific growth rate of Chlamydomonas reinhardtii and Chlorella sorokiniana decreased under square-wave light/dark cycles of medium duration, 13–87 s, in comparison to continuous illumination. Three experiments were done in three different turbidostats at saturating and sub-saturating light intensities during the light period, 240–630 μmol m⁻² s⁻¹. Within each experiment the light intensity during the light periods of the intermittent light regimes was equal and this intensity was also applied under continuous illumination. The specific growth rate decreased proportional or more than proportional to the fraction of time the algae were exposed to light; this light fraction ranged from 0.32 to 0.88. We conclude that under these light regimes the chlorophyta C. reinhardtii and C. sorokiniana are not able to store light energy in the light period to sustain growth in the dark period at the same rate as under continuous illumination. C. reinhardtii increased its specific light absorbing surface by increasing its chloropyll-a content under light/dark cycles of 13 s duration and a light fraction of 0.67 at 240 μmol m⁻² s⁻¹; the chloropyll-a content was twice as high under intermittent illumination in comparison to continuous illumination. The combination of a higher specific light absorption together with a lower specific growth rate led to a decrease of the yield of biomass on light energy under intermittent illumination.     

A light distribution model for an internally radiating photobioreactor

Analysis of light energy distribution in culture is important for maximizing the growth efficiency of photosynthetic cells and the productivity of a photobioreactor. To characterize the irradiance conditions in a photobioreactor, we developed a light distribution model for a single-radiator system and then extended the model to multiple radiators using the concept of parallel translation. Mathematical expressions for the local light intensity and the average light intensity were derived for a cylindrical photobioreactor with multiple internal radiators. The proposed model was used to predict the irradiance levels inside an internally radiating photobioreactor using Synechococcus sp. PCC 6301 as a model photosynthetic microorganism. The effects of cell density and radiator number were interpreted through photographic and model simulation studies. The predicted light intensity values were found to be very close to those obtained experimentally, which suggests that the proposed model is capable of accurately interpreting the local light energy profiles inside the photobioreactor system. Due to the simplicity and flexibility of the proposed model, it was also possible to predict the light conditions in other complex photobioreactors, including optical-fiber and pond-type photobioreactors.     

Growth of Spirulina platensis enhanced under intermittent illumination

The growth characteristics of microalgae under different light conditions (continuous or intermittent) are essential information for photobioreactor design and operation. In this study, we constructed a thin-layer (10 mm) flat plate photobioreactor device with a light/dark (L/D) alternation system to investigate the growth of Spirulina platensis under two different light regimes: (1) continuous illumination in a wide range of light intensities (1.00-77.16 mW cm⁻²); (2) intermittent illumination in medium frequency (0.01-20 Hz). Specific growth rate and light efficiency based on biomass production were determined for each round of experiment. Four regions (light limited region, intermediate region, light saturated region and light inhibition region) were recognized according to the results under continuous illumination. Under intermittent illumination, when L/D frequency increased from 0.01 Hz to 20 Hz, specific growth rate and light efficiency were enhanced. However, the enhancement was different, depending on the applied light intensity and light fraction. The higher the light intensity, the greater the enhancement would be when L/D frequency increased from 0.01 Hz to 20 Hz; and the higher the light intensity, the lower the light fractions is needed to maintain light efficiency as high as that under continuous illumination in light limited region.     

A photobioreactor with pH control: demonstration by growth of the marine diatom Skeletonema costatum

A photobioreactor with pH control for cultivation of algae isdescribed. The magnetically stirred culture flask is connectedto separate reservoirs for medium and for acid and base (dilutedHCl and NaOH, respectively). A pH electrode is inserted intothe culture flask and coupled to a pH controller, which activatesacid and base titration at set points of pH 8.1 and 7.8, respectively.Illumination is provided by light tubes with a diel light :dark cycle. The use of the photobioreactor in batch mode isillustrated by showing pH curves in different growth phasesof the marine diatom Skeletonema costatum. The photobioreactorcan also be run as a semicontinuous or continuous reactor withslight modifications.     

Lasers-an effective artificial source of radiation for the cultivation of anoxygenic photosynthetic bacteria

The laser diode (LD) is a unique light source that can efficiently produce all radiant energy within the narrow wavelength range used most effectively by a photosynthetic microorganism. We have investigated the use of a single type of LD for the cultivation of the well-studied anoxygenic photosynthetic bacterium, Rhodobacter capsulatus (Rb. capsulatus). An array of vertical-cavity surface-emitting lasers (VCSELs) was driven with a current of 25 mA, and delivered radiation at 860 nm with 0.4 nm linewidth. The emitted light was found to be a suitable source of radiant energy for the cultivation of Rb. capsulatus. The dependence of growth rate on incident irradiance was quantified. Despite the unusual nearly monochromatic light source used in these experiments, no significant changes in the pigment composition and in the distribution of bacteriochlorophyll between LHII and LHI-RC were detected in bacterial cells transferred from incandescent light to laser light. We were also able to show that to achieve a given growth rate in a light-limited culture, the VCSEL required only 30% of the electricity needed by an incandescent bulb, which is of great significance for the potential use of laser-devices in biotechnological applications and photobioreactor construction.     

Productivity and photosynthetic efficiency ofSpirulina platensis as affected by light intensity,algal density and rate of mixing in a flat plate photobioreactor

The effect of the rate of mixing on productivity of algal mass in relation to photon flux density and algal concentration was quantitatively evaluated in cultures ofSpirulina platensis grown in a newly designed flat-plate photobioreactor. Special emphasis was placed on elucidating the principles underlying efficient utilization of high photon flux density for maximal productivity of algal-mass. Whereas the rate of mixing exerted little influence on productivity and photosynthetic efficiency in cultures of relatively low algal density, its effect became ever more significant as algal concentration was increased. Maximal mixing-enhanced cell concentrations and productivity of biomass were obtained at the highest light intensity used. At each level of incident light intensity, maximum productivity and photosynthetic efficiency could be achieved only when algal concentration and mixing rates were optimized. The higher the intensity of the light source, the higher became the optimal culture density, highest algal concentrations and productivity of biomass being obtained at the highest light intensity used. The rate of mixing required careful optimization: when too low, maximal productivity resulting from the most efficient utilization of light could not be obtained. Too high a rate of mixing resulted in cell damage and reduced output rate.Author for correspondence     

Enclosed outdoor photobioreactors: light regime,photosynthetic efficiency,scale-up,and future prospects

Enclosed outdoor photobioreactors need to be developed and designed for large-scale production of phototrophic microorganisms. Both light regime and photosynthetic efficiency were analyzed in characteristic examples of state-of-the-art pilot-scale photobioreactors. In this study it is shown that productivity of photobioreactors is determined by the light regime inside the bioreactors. In addition to light regime, oxygen accumulation and shear stress limit productivity in certain designs. In short light-path systems, high efficiencies, 10% to 20% based on photosynthetic active radiation (PAR 400 to 700 nm), can be reached at high biomass concentrations (>5 kg [dry weight] m(-3)). It is demonstrated, however, that these and other photobioreactor designs are poorly scalable (maximal unit size 0.1 to 10 m(3)), and/or not applicable for cultivation of monocultures. This is why a new photobioreactor design is proposed in which light capture is physically separated from photoautotrophic cultivation. This system can possibly be scaled to larger unit sizes, 10 to >100 m(3), and the reactor liquid as a whole is mixed and aerated. It is deduced that high photosynthetic efficiencies, 15% on a PAR-basis, can be achieved. Future designs from optical engineers should be used to collect, concentrate, and transport sunlight, followed by redistribution in a large-scale photobioreactor.