Laboratory Scale Photobioreactors

Growing phototrophic microorganisms consume light energy. These microorganisms most often suffer from light deficiency because of exponential decrease in the energy of light passing through an absorbing medium. Therefore, effective distribution of light within the cultures is needed for their intensive cultivation. This is possible in special devices called photobioreactors. The photobioreactors described in the literature are classified into several types according to their geometric features. Their advantages and drawbacks are analyzed. Criteria applicable to comparison of different photobioreactors are specified.     

Modeling photoheterotrophic growth kinetics of Rhodospirillum rubrum inrectangular photobioreactors

Based on a previously established model for radiant light transfer in photobioreactors (PBR), taking into account absorption and scattering of light, a new knowledge model for coupling radiant light energy available and local growth kinetics in PBRs for the photoheterotrophic bacteria Rhodospirillum rubrum is discussed. A revised method is presented for the calculation of the absorption and scattering coefficients. The specific characteristics of the electron-transfer chains in such microorganisms leads to definition of three different metabolic zones in the PBR, explaining the behavior of mean kinetics observed in a wide range of incident light fluxes. The model is validated in rectangular PBRs for five different carbon sources and proved robust and fully predictive. This approach can be considered for simulation and model-based predictive control of PBRs cultivating photoheterotrophic microorganisms.     

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 structured model for simulation of cultures of the cyanobacterium Spirulina platensis in photobioreactors: II. Identification of kinetic parameters under light and mineral limitations

A structured model for the culture of cyanobacteria in photobioreactors is developed on the basis of Schuster's approximations for radiative light transfer. This model is therefore limited to monodimensional geometries and kinetic aspects.Light-harvesting pigments play a crucial role in defining the profile of radiative transfer inside the culture medium and in controlling the metabolism, particularly the metabolic deviations induced by mineral limitations. Modeling therefore requires the biomass to be divided into several compartments, among which the light-harvesting compartment allows a working illuminated volume to be defined within the photobioreactor. This volume may change during batch cultures, largely decreasing as pigment concentration increases during growth but increasing as pigments are consumed during mineral limitation. This approach enables, in photobioreactors of simple parallelepipedic, geometries, kinetic parameters to be determined with high accuracy; this may then be extended to vessels of more complex geometries, such as cylindrical photobioreactors.The model is applied to controlled batch cultures of the cyanobacterium Spirulina platensis in parallelepipedic photobioreactors to assess its ability to predict the behavior of these microorganisms in conditions of light and mineral limitations. Results allowed the study of optimal operating condition for continuous cultures to be approached (c) 1992 John Wiley & Sons, Inc.     

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.     

Microalgal mass culture systems and methods: Their limitation and potential

Cultivation of microalgae using natural and man-made open-ponds istechnologically simple, but not necessary cheap due to the high downstream processing cost. Products of microalgae cultured in open-pondscould only be marketed as value-added health food supplements, specialityfeed and reagents for research. The need to achieve higher productivityand to maintain monoculture of algae led to the development of enclosedtubular and flat plate photobioreactors. Despite higher biomassconcentration and better control of culture parameters, data accumulatedin the past 25 years have shown that the illuminated areal, volumetricproductivity and cost of production in these enclosed photobioreactors arenot better than those achievable in open-pond cultures. The technicaldifficulty in sterilizing these photobioreactors has hindered their applicationfor the production of high value pharmaceutical products. The alternativeof cultivating microalgae in heterotrophic mode in sterilizable fermentorshas achieved some commercial success. The maximum specific growth ratesof heterotrophic algal cultures are in general slower than those measured inphotosynthetic cultures. The biomass productivity of heterotrophic algalcultures has yet to achieve a level that is comparable to industrialproduction of yeast and other heterotrophic microrganisms. Mixotrophiccultivation of microalage takes advantage of their ability to utilise organicenergy and carbon substrates and perform photosynthesis concurrently. Moreover, production of some algal metabolites is light regulated. Futuredesign of sterilizable bioreactors for mixotrophic cultivation of microalgaemay have to consider the organic substrate the main source of energy andlight the supplemental source of energy, a change in mindset.     

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.     

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.     

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.     

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.     

Photic Volume in Photobioreactors Supporting Ultrahigh Population Densities of the Photoautotroph Spirulina platensis

Characterization of the photic zone and light penetration depth in cultures with ultrahigh cell densities represents a major issue in mass cultures of phytoautotrophic microorganisms grown in enclosed photobioreactors. In a study of the effect of underwater optical properties on the penetration depth of photosynthetically active radiation, the inherent optical properties of algal suspensions, i.e., absorption and scattering coefficients, as well as their apparent optical properties, i.e., the reflectance and the vertical attenuation coefficient of downwelling irradiance, were determined by using high-spectral-resolution radiometric measurements. The vertical attenuation coefficient was used to estimate quantitatively the depth of light penetration into a reactor containing an ultrahigh cell density (chlorophyll concentration, up to 300,000 mg m(sup-3)). For such a high cell density, the photic volume in the reactor was found to be extremely small; nevertheless, it differed between the blue and red light (less than 0.06 mm) and the green light (about 0.5 mm). This suggests a singular role for green light under the unique circumstances existing in ultrahigh-cell-density cultures of photoautotrophs.     

Photobioreactors for mass cultivation of algae

Algae have attracted much interest for production of foods, bioactive compounds and also for their usefulness in cleaning the environment. In order to grow and tap the potentials of algae, efficient photobioreactors are required. Although a good number of photobioreactors have been proposed, only a few of them can be practically used for mass production of algae. One of the major factors that limits their practical application in algal mass cultures is mass transfer. Thus, a thorough understanding of mass transfer rates in photobioreactors is necessary for efficient operation of mass algal cultures. In this review article, various photobioreactors that are very promising for mass production of algae are discussed.     

Comparative evaluation of compact photobioreactors for large-scale monoculture of microalgae

Engineering analyses combined with experimental observations in horizontal tubular photobioreactors and vertical bubble columns are used to demonstrate the potential of pneumatically mixed vertical devices for large-scale outdoor culture of photosynthetic microorganisms. Whereas the horizontal tubular systems have been extensively investigated, their scalability is limited. Horizontal tubular photobioreactors and vertical bubble column type units differ substantially in many ways, particularly with respect to the surface–to–volume ratio, the amount of gas in dispersion, the gas–liquid mass transfer characteristics, the nature of the fluid movement and the internal irradiance levels. As illustrated for eicosapentaenoic acid production from the microalga Phaeodactylum tricornutum, a realistic commercial process cannot rely on horizontal tubular photobioreactor technology. In bubble columns, presence of gas bubbles generally enhances internal irradiance when the Sun is low on the horizon. Near solar noon, the bubbles diminish the internal column irradiance relative to the ungassed state. The optimal dimensions of vertical column photobioreactors are about 0.2 m diameter and 4 m column height. Parallel east–west oriented rows of such columns located at 36.8°N latitude need an optimal inter-row spacing of about 3.5 m. In vertical columns the biomass productivity varies substantially during the year: the peak productivity during summer may be several times greater than in the winter. This seasonal variation occurs also in horizontal tubular units, but is much less pronounced. Under identical conditions, the volumetric biomass productivity in a bubble column is 60% of that in a 0.06 m diameter horizontal tubular loop, but there is substantial scope for raising this value.     

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.     

Algal biofuels

The world is facing energy crisis and environmental issues due to the depletion of fossil fuels and increasing CO₂ concentration in the atmosphere. Growing microalgae can contribute to practical solutions for these global problems because they can harvest solar energy and capture CO₂ by converting it into biofuel using photosynthesis. Microalgae are robust organisms capable of rapid growth under a variety of conditions including in open ponds or closed photobioreactors. Their reduced biomass compounds can be used as the feedstock for mass production of a variety of biofuels. As another advantage, their ability to accumulate or secrete biofuels can be controlled by changing their growth conditions or metabolic engineering. This review is aimed to highlight different forms of biofuels produced by microalgae and the approaches taken to improve their biofuel productivity. The costs for industrial-scale production of algal biofuels in open ponds or closed photobioreactors are analyzed. Different strategies for photoproduction of hydrogen by the hydrogenase enzyme of green algae are discussed. Algae are also good sources of biodiesel since some species can make large quantities of lipids as their biomass. The lipid contents for some of the best oil-producing strains of algae in optimized growth conditions are reviewed. The potential of microalgae for producing petroleum related chemicals or ready-make fuels such as bioethanol, triterpenic hydrocarbons, isobutyraldehyde, isobutanol, and isoprene from their biomass are also presented.     

Anaerobic microbial methanol conversion in marine sediments

Methanol is an ubiquitous compound that plays a role in microbial processes as a carbon and energy source, intermediate in metabolic processes or as end product in fermentation. In anoxic environments, methanol can act as the sole carbon and energy source for several guilds of microorganisms: sulfate-reducing microorganisms, nitrate-reducing microorganisms, acetogens and methanogens. In marine sediments, these guilds compete for methanol as their common substrate, employing different biochemical pathways. In this review, we will give an overview of current knowledge of the various ways in which methanol reaches marine sediments, the ecology of microorganisms capable of utilizing methanol and their metabolism. Furthermore, through a metagenomic analysis, we shed light on the unknown diversity of methanol utilizers in marine sediments which is yet to be explored.     

Microbiological production of tocopherols: current state and prospects

Tocopherols are antioxidants that prevent various diseases caused by oxidative stress. Tocochromanols comprise four isoforms of tocopherols and four isoforms of tocotrienols but α-tocopherol is the most abundant and active isoform in human and animal tissues. Tocopherols are used as dietary supplements for human, as food preservatives, in manufacture of cosmetics, and for fortification of animal feed. Only photosynthetic cells are known to accumulate detectable concentrations of tocopherols. Tocopherols can be extracted and purified or concentrated from vegetable oils and other higher plant materials. However, the concentrations in these higher plant materials are very low and there are high proportions of the less-active homologues of tocopherols. Among the many strains of photosynthetic microorganisms known to accumulate tocopherols, Euglena gracilis is promising for commercial production of α-tocopherol. The growth rate and α-tocopherol contents are relatively high and α-tocopherol comprise more than 97% of all the tocopherols accumulated by Euglena gracilis. Although a lot of work has been done to increase the contents and composition of tocopherols in higher plants through genetic and metabolic engineering, work on genetic modification of microorganisms for increased tocopherol accumulation is scarce. Many cultivation systems have been investigated for efficient production of tocopherol by Euglena gracilis. However, those that involve heterotrophic metabolism are more promising. Bubble columns and flat-plate photobioreactors are more suitable for commercial production of tocopherols, than the tubular, internally illuminated, and open-air photobioreactors.     

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.