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.     

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.     

Comparison of four outdoor pilot-scale photobioreactors

Background

Microalgae are a potential source of sustainable commodities of fuels, chemicals and food and feed additives. The current high production costs, as a result of the low areal productivities, limit the application of microalgae in industry. A first step is determining how the different production system designs relate to each other under identical climate conditions. The productivity and photosynthetic efficiency of Nannochloropsis sp. CCAP 211/78 cultivated in four different outdoor continuously operated pilot-scale photobioreactors under the same climatological conditions were compared. The optimal dilution rate was determined for each photobioreactor by operation of the different photobioreactors at different dilution rates.

Results

In vertical photobioreactors, higher areal productivities and photosynthetic efficiencies, 19–24 g m^?2 day^?1 and 2.4–4.2 %, respectively, were found in comparison to the horizontal systems; 12–15 g m^?2 day^?1 and 1.5–1.8 %. The higher ground areal productivity in the vertical systems could be explained by light dilution in combination with a higher light capture. In the raceway pond low productivities were obtained, due to the long optical path in this system. Areal productivities in all systems increased with increasing photon flux densities up to a photon flux density of 30 mol m^?2 day^?1. Photosynthetic efficiencies remained constant in all systems with increasing photon flux densities. The highest photosynthetic efficiencies obtained were; 4.2 % for the vertical tubular photobioreactor, 3.8 % for the flat panel reactor, 1.8 % for the horizontal tubular reactor, and 1.5 % for the open raceway pond.

Conclusions

Vertical photobioreactors resulted in higher areal productivities than horizontal photobioreactors because of the lower incident photon flux densities on the reactor surface. The flat panel photobioreactor resulted, among the vertical photobioreactors studied, in the highest average photosynthetic efficiency, areal and volumetric productivities due to the short optical path. Photobioreactor light interception should be further optimized to maximize ground areal productivity and photosynthetic efficiency.

     

Scale-up and design of a pilot-plant photobioreactor for the continuous culture of Spirulina platensis

Scale-up of bioreactors has the intrinsic difficulty of establishing a reliable relationship among physical parameters involved in the design of the new bioreactor and the physiology of the cultured cells. This is more critical in those cases where a more complex operation of the bioreactor is needed, such as in photobioreactors. A key issue in the operation of photobioreactors is establishing a quantification for the interaction between external illumination, internal light distribution and cell growth. In this paper an approach to the scale-up of a photobioreactor for the culture of Spirulina platensis, based on a mathematical model describing this interaction, and the operation of a previous reactor 10 times smaller is presented. The paper describes the approach followed in the scale-up, the analysis of different design constraints, the physical realization of the new bioreactor design, innovative use of plastic material walls to improve reactor safety, and finally the corroboration of its satisfactory operation.     

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.     

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.     

A novel method using CFD to optimize the inner structure parameters of flat photobioreactors

The relationship between growth rates of algae and structure parameters of closed flat-panel photobioreactors was investigated. Ad/Ar (cross-section area of the downcomer/cross-section area of the riser), h₀ (clearance from the upper edge of the baffles to the water level), and h₁ (clearance from the lower edge of the baffles to the bottom of the reactor) were selected as the inner structure parameters. CFD (Computational Fluid Dynamics) was used to simulate the hydrodynamic parameter (TKE)_d (turbulence kinetic energy of the downcomers) and the secondary parameters ε (ratio between td and tc), tc (cycle time), and DZ (dead zones), which were deduced from the hydrodynamic parameters mentioned above. The effects of (TKE)_d, ε, tc, DZ, and the inner structure parameters on cell growth of Isochrysis galbana 3011 were analyzed using data collected in 15-L airlift flat-panel photobioreactors. A model was developed to predict algae cell growth based on these inner structure parameters, thereby providing a new method for photobioreactor optimization. Validity of the model was confirmed by experimental data of I. galbana 3011 cultured in 15-L and 300-L photobioreactors, respectively. Finally, the prospect of applying CFD to photobioreactor optimization was discussed.     

Photobioreactor for cultivation and real‐time,in‐situ measurement of O2 and CO2 exchange rates,growth dynamics,and of chlorophyll fluorescence emission of photoautotrophic microorganisms

A detailed knowledge about the dynamics of phytoplanktonic photosynthesis and respiration is crucial for the determination of primary productivity in open oceans as well as for biotechnological applications. The dynamics are best studied in photobioreactors that are able to simulate natural conditions in such, that light can be modulated not only diurnally but also mimicking effects of solar elevation angle from sunrise to sunset, variable cloudiness, light modulation in refractory sun flecks due to water waves, or light intermittence due to turbulent flow in dense suspensions. In addition, high performance photobioreactors ought to be able to monitor in real time photosynthetic and respiratory activities as well as culture growth. Here, we demonstrate performance of a newly designed bench‐top laboratory photobioreactor that meets these needs, with a study of green alga Scenedesmus quadricauda. The algal suspension was exposed to simulated daily variations of total photosynthetic active irradiance and spectral profile, with a larger proportion of red photons in the morning and evening hours. The instrument monitored automatically the culture growth by measuring the optical densities at 735 nm and 680 nm and by measuring steady state and maximal chlorophyll fluorescence emission yields. The photochemical yields were estimated from chlorophyll fluorescence data. These widely used but rather indirect yield estimates were confronted with direct measurements of oxygen evolution and consumption quantum yields. The CO₂ fluxes in and out of the culture media as well as the dissolved CO₂ in algal suspension were also recorded. The experiments demonstrated potential of the new photobioreactor to reveal minute modulations in gas exchange rates as well as to yield data for calculation of photon requirement of oxygen evolution in the suspension volume that is key technological parameter for planning of large scale photobioreactors as well as key optimization parameter for strain selection.     

Simulation of algae growth in a bench-scale bubble column reactor

The growth of the marine red microalga Porphyridium sp. in a bubble-column photobioreactor was simulated. The proposed model constitutes a dynamic integration of the kinetics of photosynthesis and photoinhibition with the fluid dynamics of the bubble column, including the effects of shear stress on the kinetics of growth. The kinetic data used in the model were obtained in independent experiments run in a thin-film photobioreactor with defined light/dark cycles. The maintenance term was modified to take into account the effects of liquid flow in the bioreactor on the growth rate. A hybrid method proposed for the approximate solution of the equations gave an appreciable reduction of the calculation time. Extrapolations of the model indicated the possibility of predicting the optimal diameter for an assembly of bubble column photobioreactors. Satisfactory fit was found with the experimental results of biomass growth in a 13-liter bubble column.     

The oxygen evolution methodology affects photosynthetic rate measurements of microalgae in well‐defined light regimes

Designing photobioreactors correctly is a must for the success of microalgal mass production. Optimal photobioreactor design requires a precise knowledge of photosynthesis dynamics in fluctuating light conditions and hence a method for the measurement of photosynthetic rates in specific light regimes. However, it is not uncommon in literature that experimental protocols used to obtain oxygen generation rates are described ambiguously and the reported rates of photosynthesis vary widely depending on the methodology. Additionally, quite a number of methods overlook certain aspects that can affect the estimated rates significantly, and can therefore affect photobioreactor design. We have developed a method based on oxygen evolution measurements that accurately determines photosynthetic rates under well‐defined light regimes. Our experimental protocol takes into account most of the issues that can affect the rates of oxygen generation, such as depletion of nutrients during the measurements and precision of the measurements. We have focused on the basic applications in photobioreactor design and used a dynamic model of photosynthesis to analyze our results and compare them with available published data. The results suggest that our oxygen evolution method is consistent. Biotechnol. Bioeng. 2010;106: 228–237. © 2010 Wiley Periodicals, Inc.     

Dynamic modelling of high biomass density cultivation and biohydrogen production in different scales of flat plate photobioreactors

This paper investigates the scaling‐up of cyanobacterial biomass cultivation and biohydrogen production from laboratory to industrial scale. Two main aspects are investigated and presented, which to the best of our knowledge have never been addressed, namely the construction of an accurate dynamic model to simulate cyanobacterial photo‐heterotrophic growth and biohydrogen production and the prediction of the maximum biomass and hydrogen production in different scales of photobioreactors. To achieve the current goals, experimental data obtained from a laboratory experimental setup are fitted by a dynamic model. Based on the current model, two key original findings are made in this work. First, it is found that selecting low‐chlorophyll mutants is an efficient way to increase both biomass concentration and hydrogen production particularly in a large scale photobioreactor. Second, the current work proposes that the width of industrial scale photobioreactors should not exceed 0.20 m for biomass cultivation and 0.05 m for biohydrogen production, as severe light attenuation can be induced in the reactor beyond this threshold. Biotechnol. Bioeng. 2015;112: 2429–2438. © 2015 The Authors. Biotechnology and Bioengineering Published by Wiley Peiodicals, Inc.     

Modelling of growth and product formation of Porphyridium purpureum

In this contribution experimental data and simulations of growth and product formation of the unicellular microalgae Porphyridium purpureum are presented. A mathematical model has been developed for a better understanding of growth and product formation in production plants. The model has been refined with the results of several cultivations in a new photobioreactor designed especially for the study of microalgal kinetics under highly defined illumination conditions. In this photobioreactor light is generated by an external light source and then distributed by means of optical fibres into an internal draft tube which also serves as irradiation element. All cultivations were performed in turbidostate mode. The influence of different light intensity changes, including stepwise change and light-dark cycles in the range from millisecond to second, has been investigated and the results were integrated into the mathematical model. The structured mathematical model consists of three levels: metabolic flux, control of macromolecules and the reactor level. A new linear optimization approach has been realized, enabling the model to describe even very different cultivation conditions. Output variables are among others the commercially interesting macromolecules of the microalgae, e.g. polysaccharides, pigments and polyunsaturated fatty acids. Thus, reliable predictions of the specific production rates of these products are possible for the production in a larger scale.     

Airlift column photobioreactors for Porphyridium sp. culturing: Part II. verification of dynamic growth rate model for reactor performance evaluation

Dynamic growth rate model has been developed to quantify the impact of hydrodynamics on the growth of photosynthetic microorganisms and to predict the photobioreactor performance. Rigorous verification of such reactor models, however, is rare in the literature. In this part of work, verification of a dynamic growth rate model developed in Luo and Al-Dahhan (2004) [Biotech Bioeng 85(4): 382-393] was attempted using the experimental results reported in Part I of this work and results from literature. The irradiance distribution inside the studied reactor was also measured at different optical densities and successfully correlated by the Lambert-Beer Law. When reliable hydrodynamic data were used, the dynamic growth rate model successfully predicted the algae's growth rate obtained in the experiments in both low and high irradiance regime indicating the robustness of this model. The simulation results also indicate the hydrodynamics is significantly different between the real algae culturing system and an air-water system that signifies the importance in using reliable data input for the growth rate model.     

From open ponds to vertical alveolar panels: the Italian experience in the development of reactors for the mass cultivation of phototrophic microorganisms

The need to develop new concepts in reactor design and the growing interest inSpirulina prompted our group to abandon open ponds in the seventies and to focus interest mainly on closed systems. Two substantially different closed photobioreactors have been developed and are at present under investigation in our Research Centre: the tubular photobioreactor (made of rigid or collapsible tubes) and the recently devised vertical alveolar panel (VAP) made of 1.6-cm-thick Plexiglas alveolar sheets.The technical characteristics of the two systems are described and discussed in relation to the main factors which regulate the growth of oxygenic photosynthetic microorganisms in closed reactors.This paper was presented at the Symposium on Applied Phycology at the Fourth International Phycological Congress, Duke University.     

Simulation of algal photobioreactors: recent developments and challenges

Widespread cultivation of phototrophic microalgae for sustainable production of a variety of renewable products, for wastewater treatment, and for atmospheric carbon mitigation requires not only improved microorganisms but also significant improvements to process design and scaleup. The development of simulation tools capable of providing quantitative predictions for photobioreactor performance could contribute to improved reactor designs and it could also support process scaleup, as it has in the traditional petro-chemical industries. However, the complicated dependence of cell function on conditions in the microenvironment, such as light availability, temperature, nutrient concentration, and shear strain rate render simulation of photobioreactors much more difficult than chemical reactors. Although photobioreactor models with sufficient predictive ability suitable for reactor design and scaleup do not currently exist, progress towards this goal has occurred in recent years. The current status of algal photobioreactor simulations is reviewed here, with an emphasis on the integration of and interplay between sub-models describing hydrodynamics, radiation transport, and microalgal growth kinetics. Some limitations of widely used models and computational methods are identified, as well as current challenges and opportunities for the advancement of algal photobioreactor simulation.     

Studies on the Growth Characteristics and Dynamic Model of Spirulina Under Continuous Culture Conditions

The growth behavior, photosynthetic productivity and carbon utilizing characteristics of filamentous cyanobacterium Spirulina platensis Geitler were investigated in continuous cultures in a 10 L internalloop airlift photobioreactor. It was found that the cell density and the amount of carbon in the reactor increased and decreased with dilution rate respectively, and the relationships among them could well be expressed by the modified Monod equation. When dilution rate was 0.45/d, the rate of cell growth and that of carbon assumption reached their maximum points 0.362 g/(L·d) and 0.177 g/(L·d) respectively. The cell growth yield against carbon was 2.050 g/g. The proposed model of continuous growth fitted the experimental data quite well.     

An integrated solar and artificial light system for internal illumination of photobioreactors

Exploitation of photosynthetic cells for the production of useful metabolites requires efficient photobioreactors. Many laboratory scale photobioreactors have been reported but most of them are extremely difficult to scale up. Furthermore, the use of open ponds and outdoor tubular photobioreactors is limited by the requirement for large spaces and the difficulty in maintaining sterile conditions. In view of this, we have designed and constructed an internally illuminated stirred tank photobioreactor. The photobioreactor is simple, heat sterilizable and mechanically agitated like the conventional stirred tank bioreactors. Furthermore, it can easily be scaled up while maintaining the light supply coefficient and thus the productivity constant. A device was installed for collecting solar light and distributing it inside the reactor through optical fibers. It was equipped with a light tracking sensor so that the lenses rotate with the position of the sun. This makes it possible to use solar light for photosynthetic cell cultivation in indoor photobioreactors. As a solution to the problems of night biomass loss and low productivity on cloudy days, an artificial light source was coupled with the solar light collecting device. A light intensity sensor monitors the solar light intensity and the artificial light is automatically switched on or off, depending on the solar light intensity. In this way, continuous light supply to the reactor is achieved by using solar light during sunny period, and artificial light at night and on cloudy days.     

Flux balancing of light and nutrients in a biofilm photobioreactor for maximizing photosynthetic productivity

This article reports a combined experimental and numerical study on the efficient operation of Porous Substrate Bioreactors. A comprehensive model integrating light transport, mass transport, and algal growth kinetics was used to understand the productivity of photosynthetic biofilms in response to delivery rates of photons and nutrients. The reactor under consideration was an evaporation driven Porous Substrate Bioreactor (PSBR) cultivating the cyanobacteria Anabaena variabilis as a biofilm on a porous substrate which delivers water and nutrients to the cells. In an unoptimized experimental case, this reactor was operated with a photosynthetic efficiency of 2.3%, competitive with conventional photobioreactors. Moreover, through a scaling analysis, the location at which the phosphate delivery rate decreased the growth rate to half of its uninhibited value was predicted as a function of microorganism and bioreactor properties. The numerical model along with the flux balancing techniques presented herein can serve as tools for designing and selecting operating parameters of biofilm based cultivation systems for maximum productivity. © 2014 American Institute of Chemical Engineers Biotechnol. Prog., 30:348–359, 2014     

Analyzing and modeling of photobioreactors by combining first principles of physiology and hydrodynamics

Mixing in photobioreactors is known to enhance biomass productivity considerably, and flow dynamics play a significant role in the reactor's performance, as they determine the mixing and the cells' movement. In this work we focus on analyzing the effects of mixing and flow dynamics on the photobioreactor performance. Based on hydrodynamic findings from the CARPT(Computer Automated Radioactive Particle Tracking) technique, a possible mechanism for the interaction between the mixing and the physiology of photosynthesis is presented, and the effects of flow dynamics on light availability and light intensity fluctuation are discussed and quantitatively characterized. Furthermore, a dynamic modeling approach is developed for photobioreactor performance evaluation, which integrates first principles of photosynthesis, hydrodynamics, and irradiance distribution within the reactor. The results demonstrate the reliability and the possible applicability of this approach to commercially interesting microalgae/cyanobacteria culture systems.     

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.