Hydrodynamic characteristics and microalgae cultivation in a novel flat‐plate photobioreactor

Flat‐plate photobioreactors (FPPBRs) are widely reported for cultivation of microalgae. In this work, a novel FPPBR mounted with inclined baffles was developed, which can make the fluid produce a “spirality” flow. The flow field and cell trajectory in the photobioreactor were investigated by using computational fluid dynamics. In addition, the cell trajectory was analyzed using a Fast Fourier transformation. The influence of height of the baffles, the angle α between the inclined baffle and fluid inlet flow direction (z), and the fluid inlet velocity on the frequency of flashing light effect and pressure drop were examined to optimize the structure parameters of the inclined baffles and operating conditions of the photobioreactor. The results showed that with inclined baffles built‐in, significant swirl flow could be generated in the FPPBR. In this way, the flashing light effect for microalgal cell could also be achieved and the photosynthesis efficiency of microalgae could be promoted. In outdoor cultivation of freshwater Chlorella sp., the maximum biomass productivity of Chlorella sp. cultivated in the photobioreactor with inclined baffles was 29.94% higher than that of the photobioreactor without inclined baffles. © 2012 American Institute of Chemical Engineers Biotechnol. Prog., 2013     

Light/dark cycles in the growth of the red microalga porphyridium sp

The effect of light/dark cycles on the growth of the red microalga Porphyridium sp. was studied in a tubular loop bioreactor with light/dark cycles of different frequencies and in two 35-L reactors: a bubble column reactor and an air-lift reactor. Photon flux densities were in the range of 50 to 300 μE m-2 s-1, and flow rates were 1 to 10 L min-1. Under conditions of low illumination and high flow rates, similar results were obtained for the bubble column and air-lift reactors. However, higher productivities-in terms of biomass and polysaccharide-were recorded in the air-lift reactor under high light intensity and low gas flow rates. The interactions of both photosynthesis and photoinhibition with the fluid dynamics in the bioreactors was taken as the main element that allowed us to interpret the differences in performance of the bubble column and the air-lift reactor. It is suggested that the cyclic distribution of dark periods in the air-lift reactor facilitates better recovery from the photoinhibition damage suffered by the cells. Copyright 1998 John Wiley & Sons, Inc.     

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.     

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.     

Optimisation of cultivation parameters in photobioreactors for microalgae cultivation using the A-stat technique

Light availability inside the reactor is often the bottleneck in microalgal cultivation and for this reason much attention is being given to light limited growth kinetics of microalgae, aiming at the increase of productivity in photobioreactors. Steady-state culture characteristics are commonly used for productivity optimisation and for cell physiology studies in continuous cultures, and are normally achieved using chemostat cultivations. In the present study, we investigated the applicability of a new and dynamic cultivation method called acceleration-stat (A-stat) to microalgae cultivations where light is the limiting substrate. In the A-stat, the dilution rate is increased at a constant rate. This acceleration rate should be a compromise between a short cultivation time, in order to make it a fast process, and the metabolic adaptation rate of the microorganism to changes in the environment. Simulations of the A-stat were done with different acceleration rates to have an indication of the best rate to use. An A-stat was performed in a pilot plant bubble column (65 l) with Dunaliella tertiolecta as a model organism, and results showed that a pseudo steady state was maintained throughout the experiment. From this work, it was concluded that the A-stat can be used as a fast and accurate tool to determine kinetic parameters and to optimise any specific type of photobioreactor.     

Bubble characteristics and mass transfer in an airlift reactor with multiple net draft tubes

A pilot scale airlift reactor with multiple net draft tubes was developed. The reactor, 29?cm in diameter and 300?cm height, had four modules of double net draft tubes. Bubble size, bubble number, gas holdup, and volumetric mass transfer coefficient were measured under different superficial air velocities. The air velocity had little effect on bubble size but had significant influence on bubble number. A bubble column was also investigated for comparison. The airlift reactor had a higher gas holdup and volumetric mass transfer coefficient than those in the bubble column. The draft tubes in the airlift reactor substantially improved the reactor performance.     

Incorporating hydrodynamics into spatiotemporal metabolic models of bubble column gas fermentation

Gas fermentation has emerged as a technologically and economically attractive option for producing renewable fuels and chemicals from carbon monoxide (CO) rich waste streams. LanzaTech has developed a proprietary strain of the gas fermentating acetogen Clostridium autoethanogenum as a microbial platform for synthesizing ethanol, 2,3-butanediol, and other chemicals. Bubble column reactor technology is being developed for the large-scale production, motivating the investigation of multiphase reactor hydrodynamics. In this study, we combined hydrodynamics with a genome-scale reconstruction of C. autoethanogenum metabolism and multiphase convection–dispersion equations to compare the performance of bubble column reactors with and without liquid recycle. For both reactor configurations, hydrodynamics was predicted to diminish bubble column performance with respect to CO conversion, biomass production, and ethanol production when compared with bubble column models in which the gas phase was modeled as ideal plug flow plus axial dispersion. Liquid recycle was predicted to be advantageous by increasing CO conversion, biomass production, and ethanol and 2,3-butanediol production compared with the non-recycle reactor configuration. Parametric studies performed for the liquid recycle configuration with two-phase hydrodynamics showed that increased CO feed flow rates (more gas supply), smaller CO gas bubbles (more gas–liquid mass transfer), and shorter column heights (more gas per volume of liquid per time) favored ethanol production over acetate production. Our computational results demonstrate the power of combining cellular metabolic models and two-phase hydrodynamics for simulating and optimizing gas fermentation reactors.     

Liquid-phase dispersion in an airlift reactor with a net draft tube

Liquid-phase dispersion in an airlift reactor with a net draft tube was considered. Four net tubes with different ratios of draft tube to reactor diameters and superficial air velocities ranged from zero to 6.05 cm/s were investigated. The sparger was a porous plate. The parameter of the dispersion effect, axial dispersion coefficient, was characterized by measuring the residence time distribution in the liquid phase with single-pulse tracer input. The values of the dispersion coefficient of the proposed airlift reactor were much higher than those of the bubble column under the same operating conditions.     

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.     

Comparative analysis of the outdoor culture of Haematococcus pluvialis in tubular and bubble column photobioreactors

The present paper makes a comparative analysis of the outdoor culture of H. pluvialis in a tubular photobioreactor and a bubble column. Both reactors had the same volume and were operated in the same way, thus allowing the influence of the reactor design to be analyzed. Due to the large changes in cell morphology and biochemical composition of H. pluvialis during outdoor culture, a new, faster methodology has been developed for their evaluation. Characterisation of the cultures is carried out on a macroscopic scale using a colorimetric method that allows the simultaneous determination of biomass concentration, and the chlorophyll, carotenoid and astaxanthin content of the biomass. On the microscopic scale, a method was developed based on the computer analysis of digital microscopic images. This method allows the quantification of cell population, average cell size and population homogeneity. The accuracy of the methods was verified during the operation of outdoor photobioreactors on a pilot plant scale. Data from the reactors showed tubular reactors to be more suitable for the production of H. pluvialis biomass and/or astaxanthin, due to their higher light availability. In the tubular photobioreactor biomass concentrations of 7.0 g/L (d.wt.) were reached after 16 days, with an overall biomass productivity of 0.41 g/L day. In the bubble column photobioreactor, on the other hand, the maximum biomass concentration reached was 1.4 g/L, with an overall biomass productivity of 0.06 g/L day. The maximum daily biomass productivity, 0.55 g/L day, was reached in the tubular photobioreactor for an average irradiance inside the culture of 130 microE/m2s. In addition, the carotenoid content of biomass from tubular photobioreactor increased up to 2.0%d.wt., whereas that of the biomass from the bubble column remained roughly constant at values of 0.5%d.wt. It should be noted that in the tubular photobioreactor under conditions of nitrate saturation, there was an accumulation of carotenoids due to the high irradiance in this reactor, their content in the biomass increasing from 0.5 to 1.0%d.wt. However, carotenoid accumulation mainly took place when nitrate concentration in the medium was below 5.0mM, conditions which were only observed in the tubular photobioreactor. A similar behaviour was observed for astaxanthin, with maximum values of 1.1 and 0.2%d.wt. measured in the tubular and bubble column photobioreactors, respectively. From these data astaxanthin productivities of 4.4 and 0.12 mg/L day were calculated for the tubular and the bubble column photobioreactors. Accumulation of carotenoids was also accompanied by an increase in cell size from 20 to 35 microm, which was only observed in the tubular photobioreactors. Thus it may be concluded that the methodology developed in the present study allows the monitoring of H. pluvialis cultures characterized by fast variations of cell morphology and biochemical composition, especially in outdoor conditions, and that tubular photobioreactors are preferable to bubble columns for the production of biomass and/or astaxanthin.     

Fluid dynamics in bubble column bioreactors: experiments and numerical simulations

Detailed measurements of multiphase flows that prevail in bioreactors tell us that different transport mechanisms are dominating on different observation scales. The consequence in terms of reactor modeling is that the processes on different scales can be treated independently. A three-dimensional, dynamical model is presented that can be used to describe bubble column bioreactors on the reactor scale. It is based on the Navier-Stokes equation system. On the next smaller scale, the dynamics of the gas phase is described in a Lagrangian way, by tracking many bubble clusters or bubbles simultaneously on their way through the reactor. The model is capable of describing bubble columns of different size and can thus be used for scale-up. Its performance is demonstrated with a production-scale beer fermentor. (c) 1996 John Wiley & Sons, Inc.     

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.     

Continuous production of citric acid with recirculation of the fermentation broth after product recovery

An airlift reactor with double net draft tubes was developed. A sparger was located between the two draft tubes. The draft tubes had a significant effect on breaking bubbles into smaller ones. The assessment of the reactor performance was based on gas holdup, mixing time, and volumetric mass transfer coefficient. The proposed reactor had higher gas holdup and volumetric mass transfer coefficient, and lower mixing time in comparison with those of the bubble column. Application of the proposed reactor to fermentation of Saccharomyces cerevisiae demonstrated that the cultivation time was significantly shortened.     

Photobioreactors for microalgal cultures: A Lagrangian model coupling hydrodynamics and kinetics

Closed photobioreactors have to be optimized in terms of light utilization and overall photosynthesis rate. A simple model coupling the hydrodynamics and the photosynthesis kinetics has been proposed to analyze the photosynthesis dynamics due to the continuous shuttle of microalgae between dark and lighted zones of the photobioreactor. Microalgal motion has been described according to a stochastic Lagrangian approach adopting the turbulence model suitable for the photobioreactor configuration (single vs. two‐phase flows). Effects of light path, biomass concentration, turbulence level and irradiance have been reported in terms of overall photosynthesis rate. Different irradiation strategies (internal, lateral and rounding) and several photobioreactor configurations (flat, tubular, bubble column, airlift) have been investigated. Photobioreactor configurations and the operating conditions to maximize the photosynthesis rate have been pointed out. Results confirmed and explained the common experimental observation that high concentrated cultures are not photoinhibited at high irradiance level. © 2015 American Institute of Chemical Engineers Biotechnol. Prog., 31:1259–1272, 2015     

Modeling of photobioreactors: Application to bubble column simulation

Photobioreactors using algae, plant cells, or photosynthetic bacteria have received considerable attention from biochemical engineers. Industry is presently engaged in developing new products and testing a new generation of algal-derived natural products such as natural dyes, polyunsaturated fatty acids and polysaccharides. The present paper is a review of some of the recent findings of the authors in the field. A mathematical representation of the growth of a photosynthetic system in an alternating light-dark regime is presented. This model integrates fluid dynamics and maintenance into the three-state "Photosynthetic Factories" model by Eilers and Peeters. The model was solved analytically and the constants were fitted to experimental data obtained in a thin film tubular reactor. The theoretical prediction that the introduction of light-dark cycles may enhance the growth was confirmed by the experimental results. The model allows predicting the collapse of cultures in photobioreactors either under light-deficit or light-excess conditions, as well as the influence of mixing on these critical phenomena. This paper presents an approach to modeling the kinetics of photosynthetic systems for photobioreactor design. Under conditions of simultaneous occurrence of photoinhibition in one region of the reactor, and photo-limitation in another, it takes into account the movement of the cells from one region to the other. The model was applied to the mathematical modeling of a 13-liter bubble column photobioreactor. Experimental data were satisfactorily fit, using the kinetic data obtained independently in the thin-film experiments. The model was extended to simulate a "farm" of photobioreactors and the results presented defining Ground Productivity, which expresses the rate of biomass production of a farm of relatively small photobioreactors per area of ground required for the installation.     

A Simple and reliable formula for assessment of maximum volumetric productivities in photobioreactors

This article establishes and discusses the consistency and the range of applicability of a simple but general and predictive analytical formula, enabling to easily assess the maximum volumetric biomass growth rates (the productivities) in several kinds of photobioreactors with more or less 15% of deviation. Experimental validations are performed on photobioreactors of very different conceptions and designs, cultivating the cyanobacterium Arthrospira platensis, on a wide range of volumes and hemispherical incident light fluxes. The practical usefulness of the proposed formula is demonstrated by the fact that it appears completely independent of the characteristics of the material phase (as the type of reactor, the kind of mixing, the biomass concentration…), according to the first principle of thermodynamics and to the Gauss‐Ostrogradsky theorem. Its ability to give the maximum (only) kinetic performance of photobioreactors cultivating many different photoautotrophic strains (cyanobacteria, green algae, eukaryotic microalgae) is theoretically discussed but experimental results are reported to a future work of the authors or to any other contribution arising from the scientific community working in the field of photobioreactor engineering and potentially interested by this approach. © 2009 American Institute of Chemical Engineers Biotechnol. Prog., 2009     

O2 transfer to pseudoplastic fermentation broths in air-lift reactors with different inner designs

The effect of two different draft tube designs on annulus air-lift reactor (AALR) performance was studied using the pseudoplastic fluid such as sodium carboxymethyl cellulose (CMC) and Streptomyces lincolnesis cultures. The results revealed that with fluids exhibiting strong pseudoplasticity, the AALR with a solid draft tube showed better capacity in O2 transfer than that of the reactor with a window draft tube. This was due to the fact that the pseudoplastic fluid in the former had higher circulating liquid velocity and thus lower apparent viscosity. An empirical equation of KLa based on the results for CMC was proposed by dimensional analysis and the least square method. The equation could also be used to estimate the O2 transfer capacity in large columns. © Rapid Science Ltd. 1998     

Enhanced algal growth rate in a Taylor vortex reactor

The rate of production of algal biomass in optically dense photobioreactors depends crucially on the temporal light exposure of microorganisms, which in turn is determined by fluid flow patterns and the quantity and spatial distribution of photosynthetically active radiation. In this report it is demonstrated that highly organized and robust toroidal flow structures known as Taylor vortices cause significant increases in the rate of biomass production, efficiency of light utilization, and CO₂ uptake, and these effects become more pronounced at higher Reynolds numbers. In light of these findings and previously reported experiments using Taylor vortex flow to culture algae, it is argued that the flashing light effect, rather than mass transport effects, is responsible for the observed increases in the rate of photosynthesis. Biotechnol. Bioeng. 2013; 110: 2140–2149. © 2013 Wiley Periodicals, Inc.     

Developments and perspectives of photobioreactors for biofuel production

The production of biofuels from microalgae requires efficient photobioreactors in order to meet the tight constraints of energy efficiency and economic profitability. Current cultivation systems are designed for high-value products rather than for mass production of cheap energy carriers. Future bioreactors will imply innovative solutions in terms of energy efficiency, light and gas transfer or attainable biomass concentration to lower the energy demand and cut down production costs. A new generation of highly developed reactor designs demonstrates the enormous potential of photobioreactors. However, a net energy production with microalgae remains challenging. Therefore, it is essential to review all aspects and production steps for optimization potential. This includes a custom process design according to production organism, desired product and production site. Moreover, the potential of microalgae to synthesize valuable products additionally to the energetic use can be integrated into a production concept as well as waste streams for carbon supply or temperature control.