Batch and semi-continuous microalgal TAG production in lab-scale and outdoor photobioreactors

Microalgal triglycerides (TAGs) represent a sustainable feedstock for food, chemical and biofuel industries. The operational strategy (batch, semi-continuous, continuous cultivations) has an impact on the TAG productivity. In this study, semi-continuous (i.e. with fixed harvesting frequency) and batch cultivations were compared on TAG production both at lab-scale and in outdoor cultivations. At lab-scale, the semi-continuous TAG productivity was highest for a cycle time of 2 days (SC1; 0.21 g L^?1 day^?1) and similar to the maximum obtained with the batch (optimal harvest time; 0.23 g L^?1 day^?1). Although TAG content was lower for SC1 (22 %) than for the batch (35 %), higher biomass productivities were obtained with SC1. Outdoors, semi-continuous cultivations were subjected to a lower degree of stress (i.e. higher amount of nitrogen present in the system relative to the given irradiance) compared to lab-scale. This yielded low and similar TAG contents (10–13 %) in the different semi-continuous runs that were outdone by the batch on both TAG content (15–25 %) and productivity (batch, 0.97–2.46 g m^?2 day^?1; semi-continuous, 0.35–0.85 g m^?2 day^?1). The lab-scale experiments showed that semi-continuous strategies, besides leading to similar TAG productivities compared to the batch, could make TAG production cost effective by valorising also non-TAG compounds. However, optimization of outdoor semi-continuous cultivations is still required. For instance, the nitrogen supply and the harvest frequency should be adjusted on the total irradiance. Additionally, future research should focus on recovery metabolism upon nitrogen resupply.     

Biomass productivity of Scenedesmus dimorphus (Chlorophyceae) was improved by using an open pond–photobioreactor hybrid system

The industrialization of microalgae-based biofuel production has been hampered by low biomass productivity of conventional open ponds. In this research, a hybrid cultivation system that combined an open pond and photobioreactor (PBR), with broth circulating between both, was introduced. The hybrid system was tested under indoor and outdoor conditions using the oleaginous microalgal species Scenedesmus dimorphus. When the PBR(s) in the hybrid system reinforced the light supply to the carbon-replete open pond the biomass reached 1.34 g l^–1, 116% higher than in the non-hybrid system. Subsequent studies showed that higher circulation speed and low volume ratio of PBR vs. open pond would further improve the hybrid effects. When applied outdoors at pilot scale, the biomass productivity of the hybrid system increased 46.3–74.3% compared with the open pond and in September was 12.5% higher than that of PBRs. These results indicate that hybrid cultivation might be a cost-effective way to improve the light usage efficiency of current open pond systems.     

Biofouling in photobioreactors for marine microalgae

The economic and/or energetic feasibility of processes based on using microalgae biomass requires an efficient cultivation system. In photobioreactors (PBRs), the adhesion of microalgae to the transparent PBR surfaces leads to biofouling and reduces the solar radiation penetrating the PBR. Light reduction within the PBR decreases biomass productivity and, therefore, the photosynthetic efficiency of the cultivation system. Additionally, PBR biofouling leads to a series of further undesirable events including changes in cell pigmentation, culture degradation, and contamination by invasive microorganisms; all of which can result in the cultivation process having to be stopped. Designing PBR surfaces with proper materials, functional groups or surface coatings, to prevent microalgal adhesion is essential for solving the biofouling problem. Such a significant advance in microalgal biotechnology would enable extended operational periods at high productivity and reduce maintenance costs. In this paper, we review the few systematic studies performed so far and applied the existing thermodynamic and colloidal theories for microbial biofouling formation in order to understand microalgal adhesion on PBR surfaces and the microalgae–microalgae cell interactions. Their relationship to the physicochemical properties of the solid PBR surface, the microalgae cell surfaces, and the ionic strength of the culture medium is discussed. The suitability and the applicability of such theories are reviewed. To this end, an example of biofouling formation on a commercial glass surface is presented for the marine microalgae Nannochloropsis gaditana. It highlights the adhesion dynamics and the inaccuracies of the process and the need for further refinement of previous theories so as to apply them to flowing systems, such as is the case for PBRs used to culture microalgae.     

Solar energy conversion efficiencies in photosynthesis: Minimizing the chlorophyll antennae to maximize efficiency

The theoretical maxima of solar energy conversion efficiencies and productivities in oxygenic photosynthesis are evaluated. These are contrasted with actual measurements in a variety of photosynthetic organisms, including green microalgae, cyanobacteria, C4 and C3 plants. Minimizing, or truncating, the chlorophyll antenna size of the photosystems can improve photosynthetic solar energy conversion efficiency and productivity up to 3-fold. Generation of truncated light-harvesting chlorophyll antenna size (tla) strains, in all classes of photosynthetic organisms would help to alleviate excess absorption of sunlight and the ensuing wasteful dissipation of excitation energy, and to maximize solar-to-product energy conversion efficiency and photosynthetic productivity in high-density mass cultivations. The tla concept may find application in the commercial exploitation of microalgae and plants for the generation of biomass, biofuels, chemical feedstocks, as well as nutraceuticals and pharmaceuticals.     

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.     

Key parameters for outdoor biomass production of Scenedesmus obliquus in solar tracked photobioreactors

The biomass productivity of Scenedesmus obliquus was investigated outdoors during all seasons in solar tracked flat panel photobioreactors (PBR) to evaluate key parameters for process optimization. CO₂ was supplied by flue gas from an attached combined block heat and power plant. Waste heat from the power plant was used to heat the culture during winter. The parameters pH, CO₂, and inorganic salt concentrations were automatically adjusted to nonlimiting levels. The optimum biomass concentration increased directly with the photosynthetic active radiation (PAR) from 3 to 5 g dry weight (DW)?L^?1 for a low PAR of 10 mol photons m^?2 day^?1 and high PAR of 40–60 mol photons m^?2 day^?1, respectively. The annual average biomass yield (photosynthetic efficiency) was 0.4?±?0.5 g DW mol^?1 photons. However, biomass yields of 1.5 g DW mol^?1 photons close to the theoretical maximum were obtained at low PAR. The productivity (including the night biomass losses) ranged during all seasons from ?5 up to 30 g DW m^?2 day^?1 with a mean productivity of 9?±?7 g DW m^?2 day^?1. Low night temperatures of the culture medium and elevated day temperatures to the species-specific optimum increased the productivity. Thus, continuous regulation of the biomass concentration and the culture temperature with regard to the fluctuating weather conditions is essential for process optimization of outdoor microalgal production systems in temperate climates.     

Sub-optimal morning temperature induces photoinhibition in dense outdoor cultures of the alga Monodus subterraneus (Eustigmatophyta)

Diel changes in photosynthetic oxygen evolution and several photochemical parameters measured by chlorophyll fluorescence quenching and induction were measured in outdoor dense cultures of the alga Monodus subterraneus (Eustigmatophyta). Cultures were maintained under two temperature regimes. In one, a rise in temperature was initiated in the morning by the increase in solar radiation up to the optimal temperature of 28 °C; in the other, a heating device was used to increase the rate of warming up in early morning. Although the two cultures were maintained at the same temperature and light intensity for most of the day, cultures exposed for only a short time to suboptimal morning temperature showed a larger decrease in almost all the photosynthetic parameters. By comparing the diel changes in maximal photochemistry efficiency of photosystem II, the electron transport rate and the photochemical and non‐photochemical chlorophyll fluorescence quenching of the cultures, we concluded that even a relatively short exposure to suboptimal morning temperatures induced photoinhibitory damage. The higher photochemical activity of the heated culture was also reflected in a significant increase in productivity, which was 60% higher in the morning heated cultures than in the non‐heated cultures.     

Outdoor cultivation of a nitrogen-fixing marine cyanobacterium,Anabaena sp. ATCC 33047

Optimization of conditions for outdoor production of the nitrogen-fixing cyanobacterium Anabaena sp. ATCC 33047 has been pursued. In open ponds operated under semi-continuous regime biomass productivity values achieved ranged from 9 g (dry weight) m(-2) per day, in winter, to over 20 g m(-2) per day, in summer, provided that key operation parameters, including cell density, were optimized. Under these conditions the efficiency of solar energy conversion by the cells was fairly constant throughout the year, with photosynthetic efficiency values higher than 2%. The cyanobacterial biomass was rich in high-value phycobiliproteins, namely allophycocyanin and phycocyanin, for which open cultures of marine Anabaena represent a most interesting production system. The performance of Anabaena cultures operated under continuous regime in a closed tubular reactor has also been assessed outdoors, in winter. Biomass productivity values similar to those obtained in the ponds have been recorded for the closed system. Additionally, under these conditions, the cells excreted to the medium large amounts of a previously characterized exopolysaccharide, at production rates as high as 35 g m(-2) per day (1.4 g l(-1) per day). Properly operated closed cultures of this strain of Anabaena appear most suitable for outdoor mass production of valuable extracellular polysaccharides.     

A theoretical consideration on oxygen production rate in microalgal cultures

Because algal cells are so efficient at absorbing incoming light energy, providing more light energy to photobioreactors would simply decrease energy conversion efficiency. Furthermore, the algal biomass productivity in photobioreactor is always proportional to the total photosynthetic rate. In order to optimize the productivity of algal photobioreactors (PBRs), the oxygen production rate should be estimated. Based on a simple model of light penetration depth and algal photosynthesis, the oxygen production rate in high-density microalgal cultures could be calculated. The estimated values and profiles of oxygen production rate by this model were found to be in accordance with the experimental data. Optimal parameters for PBR operations were also calculated using the model.     

Production of lignin peroxidase and laccase by Phlebia radiata

Summary A cultivation method using carrierbound mycelium was developed for the production of lignin-modifying enzymes by Phlebia radiata. Laccase and lignin peroxidase were produced in batch and semi-continuous cultivations. Laccase activity was clearly enhanced by veratryl alcohol. The presence of both veratryl alcohol and Tween 80 was required for lignin peroxidase production in submerged cultivations. During the course of the semi-continuous cultivations production of lignin peroxidase activity increased fourfold compared with static cultivations.     

The effect of light availability on the photosynthetic activity and productivity of outdoor cultures of Arthrospira platensis (Spirulina)

The basic requirement for establishing economically viable large-scale production of algal biomass, be it for food, feed, high-value product, or energy, is the ability to produce the biomass at a low price. To achieve this goal, an efficient production protocol is needed that ensures that the potential productivity is obtained at any given time. When productivity is defined by the ability to utilize the available solar radiation that drives photosynthesis, the production protocol must be optimized to meet this requirement. In the current study, we demonstrate that by modifying the light available to Arthrospira platensis cells cultured outdoors by a variety of options like modifying the standing biomass concentration, changing the mixing rate, or shading can change the potential photosynthetic activity and apparent activity. By optimizing the light available to algae cells under outdoor conditions, productivity can be increased by approximately 50 %, from 15.6 g m^?2 day^?1 in a culture that suffers from overexposure to light to 22.4 g m^?2 day^?1 in a culture in which light downregulation is minimized. Therefore, by using a variety of methodologies to estimate photosynthetic activity, we demonstrate that overexposing the cells to light may result in downregulation of the photosynthetic activity leading to photoinhibition and lower biomass productivity.     

Growth and biomass productivity of Scenedesmus vacuolatus on a twin layer system and a comparison with other types of cultivations

Scenedesmus is a genus of microalgae employed for several industrial uses. Industrial cultivations are performed in open ponds or in closed photobioreactors (PBRs). In the last years, a novel type of PBR based on immobilized microalgae has been developed termed porous substrate photobioreactors (PSBR) to achieve significant higher biomass density during cultivation in comparison to classical PBRs. This work presents a study of the growth of Scenedesmus vacuolatus in a Twin Layer System PSBR at different light intensities (600 μmol photons m⁻² s⁻¹ or 1000 μmol photons m⁻² s⁻¹), different types and concentrations of the nitrogen sources (nitrate or urea), and at two CO₂ levels in the gas phase (2% or 0.04% v/v). The microalgal growth was followed by monitoring the attached biomass density as dry weight, the specific growth rate and pigment accumulation. The highest productivity (29 g m⁻² d⁻¹) was observed at a light intensity of 600 μmol photons m⁻² s⁻¹ and 2% CO₂. The types and concentrations of nitrogen sources did not influence the biomass productivity. Instead, the higher light intensity of 1000 μmol photons m⁻² s⁻¹ and an ambient CO₂ concentration (0.04%) resulted in a significant decrease of productivity to 18 and 10–12 g m⁻² d⁻¹, respectively. When compared to the performance of similar cultivation systems (15–30 g m⁻² d⁻¹), these results indicate that the Twin Layer cultivation System is a competitive technique for intensified microalgal cultivation in terms of productivity and, at the same time, biomass density.

     

Kraft black liquor for improving the productivity of Spirulina biomass

Summary Mass cultivation of Spirulina for commercial application suffers from poor productivity when measured against laboratory results or theoretical projections. Wider applications of algal products require that this gap be reduced. Addition of eucalyptus kraft black liquor at a maximum of 0.1% to Spirulina cultures enhanced biomass productivity by at least 40%. The factors enhancing Spirulina biomass productivity were insoluble at low pH, of low molecular mass and stable to high temperature. Single addition of kraft black liquor in outdoor continuous cultures afforded sustained enhancement in biomass productivity for at least eight weeks.     

Prediction of volumetric productivity of an outdoor photobioreactor

Volumetric productivity of Monodus subterraneus cultivated in an outdoor pilot-plant bubble column was predicted with a mathematical model. Two border cases to model the photobioreactor were chosen. Firstly, a model with no light integration in which it is assumed that microalgae can adapt immediately to local light conditions. Secondly, full light integration implicating that microalga can convert all absorbed light with a photosynthetic yield based on average light intensity. Because temperature and light conditions in our photobioreactor changed during the day, photosynthetic yields at any combination of temperature and light intensity were needed. These were determined in repeated-batch lab-scale experiments with an experimental design. The model was evaluated in an outdoor bubble column at different natural light conditions and different temperatures. Volumetric productivities in the bubble column were predicted and compared with experimental volumetric productivities. The light integration model over-estimated productivity, while the model in which we assumed no light integration under-estimated productivity. Light integration occurred partly (47%) during the period investigated. The average observed biomass yield on light was 0.60 g.mol(-1). The model of partly light integration predicted an average biomass yield on light of 0.57 g.mol(-1) and predicted that productivity could have been increased by 19% if culture temperature would have been maintained at 24 degrees C.     

Automatic on-line growth estimation method for outdoor algal biomass production

An on-line measuring procedure for estimating productivity in outdoor algal cultures was developed and tested experimentally. The procedure is based on a previously described method for on-line measuring net O(2) production rate (OPR). The data obtained by this method was found to correlate well with the conventional procedures for estimation productivity by measuring the changes in biomass concentration in the culture. The new procedure seems to be superior to the latter since it can be carried out in an almost continuous way and can give immediate indication on the productivity. OPR could be used to monitor on-line the photosynthetic and/or respiration activity in small research fermentors or in large-scale open systems outdoors.     

Scale‐down of continuous protein producing Saccharomyces cerevisiae cultivations using a two‐compartment system

In the biotechnological industry, economic decisions in investment are typically based on laboratory‐scale experiments. Scale‐down as a tool is therefore of high industrial importance to transfer the processes into larger production scale without loss in performance. In this study, large‐scale prolonged continuous cultivations with a heterologous protein producing Saccharomyces cerevisiae strain have been scaled‐down to a two‐compartment scale‐down reactor system. The effects of glucose, pH, and oxygen concentration gradients have been investigated by comparison with corresponding 300 mL standard continuous cultivations. It was found that substrate gradients within a limited range result in increased productivity of the heterologous protein under regulation of glycolytic TPI promoter and delay the decrease of protein and trehalose production during continuous cultivation. Based on these results, it is argued that introduction of variations in substrate concentration can be beneficial for industrial continuous cultivations. © 2015 American Institute of Chemical Engineers Biotechnol. Prog., 32:152–159, 2016     

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.     

Impacts of seabird-derived nutrients on water quality and diatom assemblages from Cape Vera,Devon Island,Canadian High Arctic

Relationships between key phytoplankton attributes including Chl a-specific light absorption, pigment composition and concentration, photosynthesis, primary production and community structure were studied in two open shallow nutrient-poor coastal systems receiving similar amounts of sewage water. Both systems were significantly nitrogen limited. However, differences in wastewater treatment (primary vs secondary) and sewage dilution (50%) between the two systems caused a greater difference between systems than locally around the outflows. For both systems, water at the outlet had significantly lower water transparency caused by a 20% higher absorption by coloured dissolved organic matter. Nutrient concentrations were also elevated, gradually decreasing with distance north (governing current) of the outflows, causing higher abundance of nano-sized phytoplankton, higher content of carotenoid pigments, 20–50% higher Chl a-specific absorption coefficients and higher photosynthetic capacity. Although maximum rates of Chl a-normalised photosynthesis were strongly related to nitrate availability, no effects were found on the derived areal primary production or algal biomass suggesting that photosynthetic and optical parameters are more sensitive indicators of nutrient enrichment than biomass or productivity. Handling editor: Tasman Peter Crowe     

Improved productivity by reduction of the content of light-harvesting pigment in Chlamydomonas perigranulata

The effects on productivity of the light-harvesting pigment in cells of themarine Chlamydomonas perigranulata were examined using thewild type and a mutant with a lower level of the light-harvesting pigment(LHC-1). We confirmed the photosynthetic characteristics of the wild typeand LHC-1, and these were retained generally in the continuous culturesused for evaluating productivity. The maximum productivity was 1.5 timeshigher in LHC-1 than that in the wild type. The photosynthetic productivityefficiency was higher in LHC-1 than in the wild type. These resultsindicate that the improvement in productivity can be attributed to theimproved photosynthetic productivity efficiency. We conclude that thetechnique of reducing the content of light-harvesting pigment is not onlyavailable for blue-green microalgae, but also for green microalgae.     

Ultrahigh-cell-density heterotrophic cultivation of the unicellular green microalga Scenedesmus acuminatus and application of the cells to photoautotrophic culture enhance biomass and lipid production

Although production of biodiesels from microalgae is proved to be technically feasible, a commercially viable system has yet to emerge. High-cell-density fermentation of microalgae can be coupled with photoautotrophic cultivation to produce oils. In this study, by optimizing culturing conditions and employing a sophisticated substrate feed control strategy, ultrahigh-cell-density of 286 and 283.5 g/L was achieved for the unicellular alga Scenedesmus acuminatus grown in 7.5-L bench-scale and 1,000-L pilot-scale fermenters, respectively. The outdoor scale-up experiments indicated that heterotrophically grown S. acuminatus cells are more productive in terms of both biomass and lipid accumulation when they are inoculated in photobioreactors for lipid production as compared to the cells originally grown under photoautotrophic conditions. Technoeconomic analysis based on the pilot-scale data indicated that the cost of heterotrophic cultivation of microalgae for biomass production is comparable with that of the open-pond system and much lower than that of tubular PBR, if the biomass yield was higher than 200 g/L. This study demonstrated the economic viability of heterotrophic cultivation on large-scale microalgal inocula production, but ultrahigh-productivity fermentation is a prerequisite. Moreover, the advantages of the combined heterotrophic and photoautotrophic cultivation of microalgae for biofuels production were also verified in the pilot-scale.