Photobioreactor engineering: Design and performance

This review summarizes the recent advances in high-density algal cultures in the field of algal biotechnology. Photobioreactor engineering for economical and effective utilization of algae and its products has made impressive and promising progress. Bioprocess engineers have expedited the design and the operation of algal cultivation systems. Many of them in use today are open systems due to cost considerations, and closed photobioreactors have recently attracted a considerable attention for the production of valuable biochemicals or for special applications. For high-density cultures, the optimization of environmental factors in the photobioreactors have been explored, including light delivery, CO₂ and O₂ gas transfer, medium supply, mixing and temperature. It is expected that further advanced photobioreactor engineering will enable the commercialization of noble algal products within the next decade.     

Microalgal bioreactors: Challenges and opportunities

Cultivating and harvesting of products from microalgae has led to increasing commercial interest in their use for producing valuable substances for food, feed, cosmetics, pharmaceuticals, and biodiesel, as well as for mitigation of pollution and rising CO₂ in the environment. This review outlines different bioreactors and their current status, and points out their advantages and disadvantages. Compared with open‐air systems, there are distinct advantages to using closed systems, but technical challenges still remain. In view of potential applications, development of a more controllable, economical, and efficient closed culturing system is needed. Further developments still depend on continued research in the design of photobioreactors and break‐throughs in microalgal culturing technologies.     

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.     

A novel genetic engineering platform for the effective management of biological contaminants for the production of microalgae

Microalgal cultivation that takes advantage of solar energy is one of the most cost‐effective systems for the biotechnological production of biofuels, and a range of high value products, including pharmaceuticals, fertilizers and feed. However, one of the main constraints for the cultivation of microalgae is the potential contamination with biological pollutants, such as bacteria, fungi, zooplankton or other undesirable microalgae. In closed bioreactors, the control of contamination requires the sterilization of the media, containers and all materials, which increases the cost of production, whereas open pond systems severely limits the number of species that can be cultivated under extreme environmental conditions to prevent contaminations. Here, we report the metabolic engineering of Chlamydomonas reinhardtii to use phosphite as its sole phosphorus source by expressing the ptxD gene from Pseudomonas stutzeri WM88, which encodes a phosphite oxidoreductase able to oxidize phosphite into phosphate using NAD as a cofactor. Engineered C. reinhardtii lines are capable of becoming the dominant species in a mixed culture when fertilized with phosphite as a sole phosphorus source. Our results represent a new platform for the production of microalgae, potentially useful for both closed photobioreactors and open pond systems without the need for using sterile conditions nor antibiotics or herbicides to prevent contamination with biological pollutants.     

Features of transformation of phosphates in Rhodobacter sphaeroides chromatophores

We have found the ATP production in the Rhodobacter sphaeroides chromatophores illuminated by single short light flash, that is under conditions when the proton gradient formed as a result of electron transport after the second flash, is absent. The ATP synthesis was accompanied by the H2O2 formation. Simultaneous formation of H2O2 is indicative of the oxidative activation of phosphate during the ATP synthesis, as in the model systems with isolated chlorophyll. These data provide a theoretical background to the fitting of illumination parameters in both laboratory and industrial photobioreactors with photosynthetic bacteria used in biotechnological processes.     

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.     

Biotechnology of algal biomass production: a review of systems for outdoor mass culture

Microalgae are very efficient solar energy converters and they can produce a great variety of metabolites. Man has always tried to take advantage of these proporties through algal mass culture. Despite the fact that many applications for microalgae have been described in the literature, these micro-organisms are still of minor economic importance. Industrial reactors for algal culture are at present, all designed as open race-ways (shallow open ponds where culture is circulated by a paddle-wheel). Technical and biological limitations of these open systems have given rise to the development of enclosed photoreactors (made of transparent tubes, sleeves or containers and where light source may be natural or artificial). The present review surveys advances in these two technologies for cultivation of microalgae. Starting from published results, the advantages and disadvantages of open systems and closed photobioreactors are discussed. A few open systems are presented for which particularly reliable results are available. Emphasis is then put on closed systems, which have been considered as capital intensive and are justified only when a fine chemical is to be produced.     

High-density algal photobioreactors using light-emitting diodes

Lack of high-density algal photobioreactors (PBR) has been a limitation in exploiting the biotechnological potential of algae. Recent developments of highly efficient light-emitting diodes (LED using gallium aluminum arsenide chips) have made the development of a small LED-based PBR possible. We have calculated theoretical values of gas mass transfer requirements and light-intensity requirement to support high-density algal cultures for the 680 nm monochromatic red light from LED as a light source. A prototype PBR has been designed based on these calculations. A cell concentration of more than 2 x 10(9) cells/mL (more than 6.6% v%sol;v), cell doubling times as low as 12 h, and an oxygen production rate as high as 10 mmol oxygen/L culture/h were achieved using on-line ultrafiltration to periodically provide fresh medium. (c) 1994 John Wiley & Sons, Inc.     

From laboratory to commercial production: a case study of a Spirulina (Arthrospira) facility in Musina, South Africa

Until recently, most large commercial scale microalgal production systems employed open systems. However, several large-scale closed systems have now been built and, for the first time, actual comparisons can be made. There are major operational differences between open and closed photobioreactors and, consequently, the growth physiology of the microalgae is different between the two systems. Several of the factors governing growth can, within certain boundaries, be manipulated while others are specific to the cultivation system. Crucial factors are the optical depth, turbulence, light acclimated state of the organism, nutrient availability and metabolite accumulation. In the final analyses, systems are used for specific purposes and each will determine which system is the most suitable, since there is no universal all-purpose photobioreactor.     

Factors governing algal growth in photobioreactors: the “open” versus “closed” debate

Until recently, most large commercial scale microalgal production systems employed open systems. However, several large-scale closed systems have now been built and, for the first time, actual comparisons can be made. There are major operational differences between open and closed photobioreactors and, consequently, the growth physiology of the microalgae is different between the two systems. Several of the factors governing growth can, within certain boundaries, be manipulated while others are specific to the cultivation system. Crucial factors are the optical depth, turbulence, light acclimated state of the organism, nutrient availability and metabolite accumulation. In the final analyses, systems are used for specific purposes and each will determine which system is the most suitable, since there is no universal all-purpose photobioreactor.     

Bioreactor design for photofermentative hydrogen production

Hydrogen will become a significant fuel in the near future. Photofermentative production of hydrogen is a promising and sustainable process. The design, construction and successful operation of the photobioreactors are of critical importance for photofermentative hydrogen production and became a major field of research where novel technologies are developed and adapted frequently. This paper gives an overview of the design aspects related to photobioreactors giving particular attention to design limitations, construction material, type, operating mode and scale-up. Sub-components of the overall system setup such as mixing, temperature control and hydrogen collection are also discussed. Recent achievements in the photobioreactor technologies are described.     

封闭式光生物反应器研究进展

国际上80～90年代,封闭式光生物反应器是微藻生物技术的重要研究热点,也是微藻生物技术产业化的关键技术之一。本文较全面地介绍了用于微藻大规模培养的封闭式光生物反应器研究现状。将封闭式光生物反应器分为柱式、管式、板式和光导纤维反应器等类型。工业放大前景的管式和板式光生物反应器采取了典型个案分析的方法,列表比较了典型反应器的主要技术参数,并对它们的技术发展趋势进行了归纳总结。     

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.     

Design and construction of a photobioreactor for hydrogen production,including status in the field

Several species of microalgae and phototrophic bacteria are able to produce hydrogen under certain conditions. A range of different photobioreactor systems have been used by different research groups for lab-scale hydrogen production experiments, and some few attempts have been made to upscale the hydrogen production process. Even though a photobioreactor system for hydrogen production does require special construction properties (e.g., hydrogen tight, mixing by other means than bubbling with air), only very few attempts have been made to design photobioreactors specifically for the purpose of hydrogen production. We have constructed a flat panel photobioreactor system that can be used in two modes: either for the cultivation of phototrophic microorganisms (upright and bubbling) or for the production of hydrogen or other anaerobic products (mixing by “rocking motion”). Special emphasis has been taken to avoid any hydrogen leakages, both by means of constructional and material choices. The flat plate photobioreactor system is controlled by a custom-built control system that can log and control temperature, pH, and optical density and additionally log the amount of produced gas and dissolved oxygen concentration. This paper summarizes the status in the field of photobioreactors for hydrogen production and describes in detail the design and construction of a purpose-built flat panel photobioreactor system, optimized for hydrogen production in terms of structural functionality, durability, performance, and selection of materials. The motivations for the choices made during the design process and advantages/disadvantages of previous designs are discussed.     

Specific Features of Phosphate Transformation on Rhodobacter sphaeroides Chromatophores

ATP production has been shown to take place on illumination of Rhodobacter sphaeroides chromatophores by a single light flash, i.e., in the absence of a proton gradient (which would form as a result of electron transport should a second flash occur). ATP synthesis was accompanied by H₂O₂ formation. Simultaneous formation of ATP and H₂O₂ is indicative of oxidative activation of phosphate during ATP synthesis, as in model systems with isolated chlorophyll. These data provide a theoretical background for selecting illumination parameters in laboratory and industrial photobioreactors used for cultivation of photosynthetic bacteria in biotechnological processes.     

Are white-rot fungi a real biotechnological option for the improvement of environmental health?

The use of white-rot fungi as a biotechnological tool for cleaning the environment of recalcitrant pollutants has been under evaluation for several years. However, it is still not possible to find sufficiently detailed investigations of this subject to conclude that these fungi can decontaminate the environment. In the present review, we have summarized and discussed evidence about the potential of white-rot fungi to degrade such pollutants as polycyclic aromatic hydrocarbons, dyes or antibiotics as an example of the complex structures that these microorganisms can attack. This review also discusses field experiment results and limitations of white-rot fungi trials from contaminated sites. Moreover, the use of catabolic potential of white-rot fungi in biopurification systems (biobeds) is also discussed. The current status and future perspectives of white-rot fungi, as a viable biotechnological alternative for improvement of environmental health are noted.     

Biotechnological applications of image analysis: present and future prospects.

The current and potential biotechnological applications of image analysis and image processing systems are reviewed. Image analysis systems have proven to be highly versatile and efficient tools for assisting academic biotechnological research. It is expected that image analysis systems will allow more rapid and accurate quantification of numerous biotechnological analyses. There is, therefore, much scope for the implementation of image analysis/processing systems in a large variety of industrial and clinical applications.     

Immobilized Growth of the Peridinin-Producing Marine Dinoflagellate Symbiodinium in a Simple Biofilm Photobioreactor

Products from phototrophic dinoflagellates such as toxins or pigments are potentially important for applications in the biomedical sciences, especially in drug development. However, the technical cultivation of these organisms is often problematic due to their sensitivity to hydrodynamic (shear) stress that is a characteristic of suspension-based closed photobioreactors (PBRs). It is thus often thought that most species of dinoflagellates are non-cultivable at a technical scale. Recent advances in the development of biofilm PBRs that rely on immobilization of microalgae may hold potential to circumvent this major technical problem in dinoflagellate cultivation. In the present study, the dinoflagellate Symbiodinium voratum was grown immobilized on a Twin-Layer PBR for isolation of the carotenoid peridinin, an anti-cancerogenic compound. Biomass productivities ranged from 1.0 to 11.0 g m^?2 day^?1 dry matter per vertical growth surface and a maximal biomass yield of 114.5 g m^?2, depending on light intensity, supplementary CO₂, and type of substrate (paper or polycarbonate membrane) used. Compared to a suspension culture, the performance of the Twin-Layer PBRs exhibited significantly higher growth rates and maximal biomass yield. In the Twin-Layer PBR a maximal peridinin productivity of 24 mg m^?2 day^?1 was determined at a light intensity of 74 μmol m^?2 s^?1, although the highest peridinin content per dry weight (1.7 % w/w) was attained at lower light intensities. The results demonstrate that a biofilm-based PBR that minimizes hydrodynamic shear forces is applicable to technical-scale cultivation of dinoflagellates and may foster biotechnological applications of these abundant marine protists.