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.     

Photosynthetic productivity of conical helical tubular photobioreactors incorporating Chlorella sp. under various culture medium flow conditions

The characteristics of the flow of culture medium significantly affects the photosynthetic productivity of bioreactors incorporating microalgae. Therefore, in order to optimize the performance of a conical helical tubular photobioreactor (CHTP) designed to be useful in practical applications, we characterized the flow pattern of the culture medium through the reactor. The effects of medium flow conditions on the photosynthetic productivity of Chlorella sp. were investigated using several different CHTP units with 0.50-m2 installation areas which were designed to vary the direction and rate of flow driven by airlift. In addition, the performance of two- and four-unit systems constructed by combining individual CHTP units was evaluated. We found that when medium flowed from the bottom to the top of the photostage, it exhibited smoother flow of culture medium than when flowing from top to bottom, which led to higher photosynthetic productivity by the former. Consistent with theoretical calculations, varying the lengths of vertical flow passages caused flow rates to vary, and higher flow rates meant smoother circulation of medium and better photosynthetic performance. Flow of medium through a four-unit CHTP system was similar to that in single units, enabling a photosynthetic productivity of 31.0 g-dry biomass per m2-installation area per day to be achieved, which corresponded to a photosynthetic efficiency of 7.50% (photosynthetically active radiation (PAR; 400-700 nm)). This high photosynthetic performance was possible because smoother medium flow attained in single units was also attained in the four-unit system.     

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.     

Comparison of photobioreactors for cultivation of Undaria pinnatifida gametophytes

Undaria pinnatifida gametophytes were grown in 2.5 l bubble column and airlift reactor at 25 °C and light intensity of 40 mol m^–2 s^–1 for 6 days. With aeration at 1 l min^–1, the airlift reactor yielded higher growth rate (0.12 mg DW ml^–1 d^–1) than a bubble column (0.08 mg DW ml^–1 d^–1). The advantages were related to the more homogeneous fluid dynamic characteristics of the airlift reactor.     

Modelling epilithic biofilms combining hydrodynamics,invertebrate grazing and algal traits

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The influence of vessel height and top-section size on the hydrodynamic characteristics of airlift fermentors

Fermentations of the yeast Saccharomyces cerevisiae were carried out in a 90 to 250-L working volume concentric tube airlift fermentor. Measurements of liquid circulation velocity, gas hold-up, and liquid mixing were made under varying conditions of gas flowrate, vessel height, and top-section size. Both liquid circulation velocity and mixing time increased with vessel height. Liquid velocity varied approximately in proportion to the square root of column height, supporting a theoretically based relationship. The effect of vessel height on gas hold-up was negligible. The height of the top-section had a significant effect on liquid mixing. Mixing time decreased with increasing size of the top-section up to a critical height. As the top-section was expanded beyond this height, little improvement in mixing was seen. This indicated the presence of a two-zone flow pattern in the top-section. Liquid velocity and gas hold-up were essentially independent of top-section height. (c) 1994 John Wiley & Sons, Inc.     

Improved antifouling properties of photobioreactors by surface grafted sulfobetaine polymers

To improve the antifouling (AF) properties of photobioreactors (PBR) for microalgal cultivation, using trihydroxymethyl aminomethane (tris) as the linking agent, a series of polyethylene (PE) films grafted with sulfobetaine (PE-SBMA) with grafting density ranging from 23.11 to 112 μg cm^?2 were prepared through surface-initiated atom transfer radical polymerization (SI-ATRP). It was found that the contact angle of PE-SBMA films decreased with the increase in the grafting density. When the grafting density was 101.33 μg cm^?2, it reached 67.27°. Compared with the PE film, the adsorption of protein on the PE-SBMA film decreased by 79.84% and the total weight of solid and absorbed microalgae decreased by 54.58 and 81.69%, respectively. Moreover, the transmittance of PE-SBMA film recovered to 86.03% of the initial value after cleaning, while that of the PE film recovered to only 47.27%. The results demonstrate that the AF properties of PE films were greatly improved on polySBMA-grafted surfaces.     

Outdoor helical tubular photobioreactors for microalgal production: modeling of fluid-dynamics and mass transfer and assessment of biomass productivity

The production of the microalga Phaeodactylum tricornutum in an outdoor helical reactor was analyzed. First, fluid dynamics, mass-transfer capability, and mixing of the reactor was evaluated at different superficial gas velocities. Performance of the reactor was controlled by power input per culture volume. A maximum liquid velocity of 0.32 m s(-1) and mass transfer coefficient of 0.006 s(-1) were measured at 3200 W m(-3). A model of the influence of superficial gas velocity on the following reactor parameters was proposed: gas hold-up, induced liquid velocity, and mass transfer coefficient, with the accuracy of the model being demonstrated. Second, the influence of superficial gas velocity on the yield of the culture was evaluated in discontinuous and continuous cultures. Mean daily values of culture parameters, including dissolved oxygen, biomass concentration, chlorophyll fluorescence (F(v)/F(m) ratio), growth rate, biomass productivity, and photosynthetic efficiency, were determined. Different growth curves were measured when the superficial gas velocity was modified-the higher the superficial gas velocity, the higher the yield of the system. In continuous mode, biomass productivity increased by 35%, from 1.02 to 1.38 g L(-1) d(-1), when the superficial gas velocity increased from 0.27 to 0.41 m s(-1). Maximal growth rates of 0.068 h(-1), biomass productivities up to 1.4 g L(-1) d(-1), and photosynthetic efficiency of up to 15% were obtained at the higher superficial gas velocity of 0.41 m s(-1). The fluorescence parameter, F(v)/F(m), which reflects the maximal efficiency of PSII photochemistry, showed that the cultures were stressed at average irradiances within the culture higher than 280 microE m(-2) s(-1) at every superficial gas velocity. For nonstressed cultures, the yield of the system was a function of average irradiance inside the culture, with the superficial gas velocity determining this relationship. When superficial gas velocity was increased, higher growth rates, biomass productivities, and photosynthetic efficiencies were obtained for similar average irradiance values. The higher the superficial gas velocity, the higher the liquid velocity, with this increase enhancing the movement of the cells inside the culture. In this way the efficiency of the cells increased and higher biomass concentrations and productivities were reached for the same solar irradiance.     

Relationships between hydrodynamics and rheology of flocculating yeast suspensions in a high-cell-density airlift bioreactor

In this article a hydrodynamic and rheological analysis of a continuous airlift bioreactor with high-cell-density system is presented. A highly flocculating recombinant strain of Sacharomyces cerevisiae containing genes for lactose transport (lactose permease) and hydrolysis (beta-galactosidase) was exploited to ferment lactose from cheese whey to ethanol. The magnetic particle-tracer method was used to assess the effect of operational conditions (air-flow rate, biomass concentration) on hydrodynamic behavior of an airlift bioreactor during the fermentation process. Measurements of liquid circulation velocity showed the existence of a critical value of biomass concentration at which a dramatic deceleration of net liquid flow appeared with increasing biomass quantity. Rheological analysis revealed exponential increase of viscosity of the yeast floc suspension at the same biomass concentration of about 73 g/dm3 corresponding to 42.8% v/v of solid fraction. These facts have a particular importance for the successful processing of a high-cell-density airlift bioreactor as only a circulated flow regime will be favorable to keep the solid particles in suspension state and evenly distributed throughout the bioreactor.     

Investigation and modeling of the effects of light spectrum and incident angle on the growth of Chlorella vulgaris in photobioreactors

An in‐depth investigation of how various illumination conditions influence microalgal growth in photobioreactors (PBR) has been presented. Effects of both the light emission spectrum (white and red) and the light incident angle (0° and 60°) on the PBR surface were investigated. The experiments were conducted in two fully controlled lab‐scale PBRs, a torus PBR and a thin flat‐panel PBR for high cell density culture. The results obtained in the torus PBR were used to build the kinetic growth model of Chlorella vulgaris taken as a model species. The PBR model was then applied to the thin flat‐panel PBR, which was run with various illumination conditions. Its detailed representation of local rate of photon absorption under various conditions (spectral calculation of light attenuation, incident angle influence) enabled the model to take into account all the tested conditions with no further adjustment. This allowed a detailed investigation of the coupling between radiation field and photosynthetic growth. Effects of all the radiation conditions together with pigment acclimation, which was found to be relevant, were investigated in depth. © 2016 American Institute of Chemical Engineers Biotechnol. Prog., 32:247–261, 2016     

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.     

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.     

Minimization of carbon losses in pilot-scale outdoor photobioreactors by model-based predictive control

The optimization of carbon use in pilot-scale outdoor tubular photobioreactors is investigated in this study. The behavior of a 0.20-m(3) tubular photobioreactor was studied, with and without algae, by steady-state and pulse dynamic-response analysis experiments. A model of the system was obtained and implemented in a programmable control unit and was used to control the reactor under normal production conditions. Results showed that, using and on-off control, the mean daily CO(2) flow in the reactor was 0.86 g min(-1), 19.7% of this being lost. By using a predictive control algorithm the mean daily CO(2) flow was reduced to 0.74 g min(-1), with losses being reduced to 15.6%. In this case, pH tracking was not adequate, especially at the beginning and end of the daylight period, because the variation in solar irradiance was not considered. Taking solar irradiance into account resulted in better performance, with mean daily CO(2) flow reduced to 0.70 g min(-1), and carbon losses reduced to 5.5%. pH tracking was improved and valve actuation was reduced. Improvement of pH control reduced pH gradients in the culture, which increased the photosynthesis rate and biomass productivity of the system. Biomass productivity increased from 1.28 to 1.48 g L(-1) day-(1) when on-off control was replaced by model-based predictive control plus solar irradiance effect mode. Implementation of this methodology in outdoor photobioreactors can increase productivity by 15% and reduce the cost of producing biomass by >6%. Clearly, application of effective control techniques, such as model-based predictive control (MPC), must be considered when developing these processes.     

Comparison of artificial light photobioreactors and other production systems using Porphyridium cruentum

A new type of preparative photobioreactor for high quality production of microalgae is developed for hatchery-nursery of marine animals, as well as for fine chemicals extraction. Of modular conception, two artificial light photobioreactors in plastic and stainless steel are designed so as to provide strictly controlled conditions in an attempt to increase quality and diminish cost prices. They are assessed for production of Porphyridum cruentum and compared to conventional transparent tanks and solar photobioreactors. The concentration and productivity obtained are ten-fold higher than with hatchery tanks, which leads to a significant drop in cost price of biomass. Comparison is also made with a 10 m² solar photobioreactor operated in the south of France, for which biomass cost price is half that of 1.5 m² artificial light photobioreactor. Extrapolations erasing size discrepancy show that the cost price of the two technologies are not very different. This revised version was published online in June 2006 with corrections to the Cover Date.     

Continuous production of diatom Entomoneis sp. in mechanically stirred tank and flat-panel airlift photobioreactors

Continuous production of diatom Entomonies sp. was performed in mechanically stirred tank and flat-panel airlift photobioreactors (FPAP). The maximum specific growth rate of diatom from the batch experiment was 0.98 d^?1. A series of dilution rate and macronutrient concentration adjustments were performed in a stirred tank photobioreactor and found that the dilution rate ranged from 0.7 to 0.8 d^?1 and modified F/2 growth media containing nitrate at 3.09?mg N/L, phosphate at 2.24?mg P/L, and silicate at 11.91?mg Si/L yielded the maximum cell number density. Finally, the continuous cultivation of Entomonies sp. was conducted in FPAP using the optimal conditions determined earlier, resulting in the maximum cell number density of 19.69?×?10⁴ cells/mL, which was approximately 47 and 73% increase from the result using the stirred tank photobioreactor fed with modified and standard F/2 growth media, respectively.     

流溪河水库水动力学对营养盐和浮游植物分布的影响

流溪河水库2001年年降雨量2250mm,其中79％来自4月至9月的丰水期。入库流量变幅4．25～414．00m^3／s,近60％的入库水量流来自吕田河。流域营养盐输送量取决于流域降雨径流强度,吕田河高于玉溪河。由于营养盐被泥沙吸附沉积,丰水期湖泊区营养盐浓度明显低于河流区。浮游植物密度为17～1245cells／ml,以硅藻为主要优势种群。硅藻密度分布与水流流速和透明度的相关程度明显高于与营养盐和温度的相关程度。在丰水期,由于受水流和透明度的强烈控制,尽管营养盐供应比较充足,硅藻密度处于比较低的水平。丰水期硅藻密度稍低于枯水期,河流区明显低于大坝处。浮游植物香农-威纳多样性指数为0．97～2．75。受水库水动力学(水位波动等因素)的影响,最大浮游植物多样性出现于水位波动比较大的8月份,最小值则出现于水位波动最小的6月份。     

Two-phase culture for enhanced alkaloid synthesis and release in a new airlift reactor by Catharanthus roseus

A new airlift reactor was used to culture Catharanthus roseus cells, in which the draft tube was made up of polyurethane foam and acted as the immobilizing matrix. The reactor was connected in series to an adsorbent column with a neutral polymeric resin which absorbs these alkaloids. The synthesis of alkaloid was stimulated by adding the resin column and the total content of alkaloid secreted by cells reached 380 mg/L, which was 4.5 times of that in the control experiment. Meanwhile, most of the intracellular alkaloid produced by Catharanthus roseus was secreted into the medium.     

Improvement in growth and toxin production of Alexandrium tamarense by two-step culture method

The growth and toxin content of the dinoflagellate Alexandrium tamarense ATHK was markedly affected by culture methods. In early growth phase at lower cell density static or mild agitation methods were beneficial to growth, but continuous agitation or aeration, to some extent, had an adverse effect on cell growth. Static culture in 2 L Erlenmeyer flasks had the highest growth rate (0.38 d⁻¹) but smaller cell size compared with other culture conditions. Cells grown under aerated conditions possessed low nitrogen and phosphorus cell yields, namely high N and P cell-quota. At day 18, cells grown in continuous agitated and 1 h aerated culture entered the late stationary phase and their cellular toxin contents were higher (0.67 and 0.54 pg cell⁻¹) compared with cells grown by other culture methods (0.27–0.49 pg cell⁻¹). The highest cell density and cellular toxin content were 17190 cells mL⁻¹ and 1.26 pg cell⁻¹ respectively in an airlift photobioreactor with two-step culture. The results indicate that A. tamarense could be grown successfully in airlift photobioreactor by a two-step culture method, which involved cultivating the cells statically for 4 days and then aerating the medium. This provides an efficient way to enhance cell and toxin yield of A. tamarense.     

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.