Photobioreactor

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Moss photobioreactor to cultivate mosses like Physcomitrella patens at the laboratory scale Bioreaktor quer2.jpg
Moss photobioreactor to cultivate mosses like Physcomitrella patens at the laboratory scale

A photobioreactor (PBR) refers to any cultivation system designed for growing photoautotrophic organisms using artificial light sources or solar light to facilitate photosynthesis. Photobioreactors are typically used to cultivate microalgae, cyanobacteria, and some mosses. [1] Photobioreactors can be open systems, such as raceway ponds, which rely upon natural sources of light and carbon dioxide. Closed photobioreactors are flexible systems that can be controlled to the physiological requirements of the cultured organism, resulting in optimal growth rates and purity levels. Photobioreactors are typically used for the cultivation of bioactive compounds for biofuels, pharmaceuticals, and other industrial uses. [2]

Contents

Open systems

Open raceway pond Microalgenkwekerij te Heure bij Borculo.jpg
Open raceway pond

The first approach for the controlled production of phototrophic organisms was a natural open pond or artificial raceway pond. Therein, the culture suspension, which contains all necessary nutrients and carbon dioxide, is pumped around in a cycle, being directly illuminated from sunlight via the liquid's surface. Raceway ponds are still commonly used in industry due to their low operational cost in comparison to closed photobioreactors. However, they offer an insufficient control of reaction conditions due to their reliance on environmental light supply and carbon dioxide, as well as possible contamination from other microorganisms. Using open technologies also result in losses of water due to evaporation into the atmosphere. [3]

Closed systems

The construction of closed photobioreactors avoids system-related water losses and minimises contamination. [4] Though closed systems have better productivity compared to open systems due to this, they still need to be improved to make them suitable for production of low price commodities as cell density remains low due to several limiting factors. [5] All modern photobioreactors have tried to balance between a thin layer of culture suspension, optimized light application, low pumping energy consumption, capital expenditure and microbial purity. However, light attenuation and increased carbon dioxide requirements with growth are the two most inevitable changes in phototrophic cultures that severely limits productivity of photobioreactors. [6] [5] The accumulation of photosynthetic oxygen with growth of microalgae in photobioreactors is also believed to be a significant limiting factor; however, it has been recently shown with the help of kinetic models that dissolved oxygen levels as high as 400% air saturation are not inhibitory when cell density is high enough to attenuate light at later stages of microalgal cultures. [7] Many different systems have been tested, but only a few approaches were able to perform at an industrial scale. [8]

Redesigned laboratory fermenters

The simplest approach is the redesign of the well-known glass fermenters, which are state of the art in many biotechnological research and production facilities worldwide. The moss reactor for example shows a standard glass vessel, which is externally supplied with light. The existing head nozzles are used for sensor installation and for gas exchange. [9] This type is quite common in laboratory scale, but it has never been established in bigger scale, due to its limited vessel size.

Tubular photobioreactors

Tubular glass photobioreactor Photobioreactor PBR 4000 G IGV Biotech.jpg
Tubular glass photobioreactor

Made from glass or plastic tubes, this photobioreactor type has succeeded within production scale. The tubes are oriented horizontally or vertically and are supplied from a central utilities installation with pump, sensors, nutrients and carbon dioxide. Tubular photobioreactors are established worldwide from laboratory up to production scale, e.g. for the production of the carotenoid Astaxanthine from the green algae Haematococcus pluvialis or for the production of food supplement from the green algae Chlorella vulgaris. These photobioreactors take advantage from the high purity levels and their efficient outputs. The biomass production can be done at a high quality level and the high biomass concentration at the end of the production allows energy efficient downstream processing. [10] Due to the recent prices of the photobioreactors, economically feasible concepts today can only be found within high-value markets, e.g. food supplement or cosmetics. [11]

The advantages of tubular photobioreactors at production scale are also transferred to laboratory scale. A combination of the mentioned glass vessel with a thin tube coil allows relevant biomass production rates at laboratory research scale. Being controlled by a complex process control system the regulation of the environmental conditions reaches a high level. [12]

Christmas tree photobioreactor

Christmas tree reactor 20120927 Tannenbaumreaktor.jpg
Christmas tree reactor

An alternative approach is shown by a photobioreactor, which is built in a tapered geometry and which carries a helically attached, translucent double hose circuit system. [13] The result is a layout similar to a Christmas tree. The tubular system is constructed in modules and can theoretically be scaled outdoors up to agricultural scale. A dedicated location is not crucial, similar to other closed systems, and therefore non-arable land is suitable as well. The material choice should prevent biofouling and ensure high final biomass concentrations. The combination of turbulence and the closed concept should allow a clean operation and a high operational availability. [14]

Plate photobioreactor

Plastic plate photobioreactor Photobioreactor PBR 500 P IGV Biotech.jpg
Plastic plate photobioreactor

Another development approach can be seen with the construction based on plastic or glass plates. Plates with different technical design are mounted to form a small layer of culture suspension, which provides an optimized light supply. In addition, the simpler construction compared to tubular reactors allows the use of less expensive plastic materials. From the pool of different concepts e.g. meandering flow designs or bottom gassed systems have been realized and shown good output results. Some unsolved issues are material life time stability or the biofilm forming. Applications at industrial scale are limited by the scalability of plate systems. [15]

In April 2013, the IBA in Hamburg, Germany, a building with an integrated glass plate photobioreactor facade, was commissioned. [16]

Flat Panel Airlift photobioreactor (FPA)

A side view of a FPA with double sided illumination Fpa side shot.jpg
A side view of a FPA with double sided illumination
Close view of CO2 bubbles in a double side illuminated Flat Panel Airlift Grune Phase LED 3P.jpg
Close view of CO2 bubbles in a double side illuminated Flat Panel Airlift
Stack of FPAs in a production plant from Subitec Stack of FPAs.jpg
Stack of FPAs in a production plant from Subitec

This established photobioreactor also has a plate shape. The proprietary geometry of the reactor is characterized in particular by the optimal light input with simultaneous shear-free mixing of the culture.

The variably adjustable CO2 air mixture is introduced at the bottom of the photobioreactor through a special membrane in a large number of small air bubbles. The rising of the air bubbles in the specially shaped plate reactor creates a homogeneous mixing of the culture and, on the one hand, a very long residence time of the CO2-air mixture and thus a very good CO2 input (degree of utilization) into the culture. On the other hand, the homogeneous mixing ensures a very good light input of the grow-light LEDs usually installed on both sides of the system and thus a very high utilization of the light energy.

Since the geometry of the reactor integrates one or more down chambers that transport the culture from the top area around to the bottom area, the culture is constantly homogeneously supplied with the photosynthesis-relevant factors, thus achieving a high productivity.

The reactor was developed at the renowned Fraunhofer Institute in Germany and manufactured by Subitec GmbH.

Horizontal photobioreactor

Horizontal photobioreactor with zigzag shaped geometry Horizontal-Photobioreaktor mit Zick-Zack-formigen Vertiefungen.png
Horizontal photobioreactor with zigzag shaped geometry

This photobioreactor type consists of a plate-shaped basic geometry with peaks and valleys arranged in regular distance. This geometry causes the distribution of incident light over a larger surface which corresponds to a dilution effect. This also helps solving a basic problem in phototrophic cultivation, because most microalgae species react sensitively to high light intensities. Most microalgae experience light saturation already at light intensities, ranging substantially below the maximum daylight intensity of approximately 2000 W/m2. Simultaneously, a larger light quantity can be exploited in order to improve photoconversion efficiency. The mixing is accomplished by a rotary pump, which causes a cylindrical rotation of the culture broth. In contrast to vertical designs, horizontal reactors contain only thin layers of media with a correspondingly low hydrodynamic pressure. This has a positive impact on the necessary energy input and reduces material costs at the same time.

Foil photobioreactor

The pressure of market prices has led the development of foil-based photobioreactor types. Inexpensive PVC or PE foils are mounted to form bags or vessels which cover algae suspensions and expose them to light. The pricing ranges of photobioreactor types have been enlarged with the foil systems. It has to be kept in mind that these systems have a limited sustainability as the foils have to be replaced from time to time. For full balances, the investment for required support systems has to be calculated as well. [17]

Porous substrate bioreactor

Porous substrate bioreactor [18] (PSBR), being developed at University of Cologne, also known as the twin-layer system, uses a new principle to separate the algae from a nutrient solution by means of a porous reactor surface on which the microalgae are trapped in biofilms. This new procedure reduces by a factor of up to one hundred the amount of liquid needed for operation compared to the current technology, which cultivates algae in suspensions. As such, the PSBR procedure significantly reduces the energy needed while increasing the portfolio of algae that can be cultivated.

Outlook

The discussion around microalgae and their potentials in carbon dioxide sequestration and biofuel production has caused high pressure on developers and manufacturers of photobioreactors. [19] Today, none of the mentioned systems is able to produce phototrophic microalgae biomass at a price which is able to compete with crude oil. New approaches test e.g. dripping methods to produce ultra-thin layers for maximal growth with application of flue gas and waste water. Further on, much research is done worldwide on genetically modified and optimized microalgae.

See also

Related Research Articles

<span class="mw-page-title-main">Bioreactor</span> System that supports a biologically active environment

A bioreactor refers to any manufactured device or system that supports a biologically active environment. In one case, a bioreactor is a vessel in which a chemical process is carried out which involves organisms or biochemically active substances derived from such organisms. This process can either be aerobic or anaerobic. These bioreactors are commonly cylindrical, ranging in size from litres to cubic metres, and are often made of stainless steel. It may also refer to a device or system designed to grow cells or tissues in the context of cell culture. These devices are being developed for use in tissue engineering or biochemical/bioprocess engineering.

<span class="mw-page-title-main">Microalgae</span> Microscopic algae

Microalgae or microphytes are microscopic algae invisible to the naked eye. They are phytoplankton typically found in freshwater and marine systems, living in both the water column and sediment. They are unicellular species which exist individually, or in chains or groups. Depending on the species, their sizes can range from a few micrometers (μm) to a few hundred micrometers. Unlike higher plants, microalgae do not have roots, stems, or leaves. They are specially adapted to an environment dominated by viscous forces.

<span class="mw-page-title-main">Algaculture</span> Aquaculture involving the farming of algae

Algaculture is a form of aquaculture involving the farming of species of algae.

<span class="mw-page-title-main">Biohydrogen</span> Hydrogen that is produced biologically

Biohydrogen is H2 that is produced biologically. Interest is high in this technology because H2 is a clean fuel and can be readily produced from certain kinds of biomass, including biological waste. Furthermore some photosynthetic microorganisms are capable to produce H2 directly from water splitting using light as energy source.

<i>Scenedesmus</i> Genus of green algae

Scenedesmus is a genus of green algae, in the class Chlorophyceae. They are colonial and non-motile. They are one of the most common components of phytoplankton in freshwater habitats worldwide.

Auxenochlorella protothecoides, formerly known as Chlorella protothecoides, is a facultative heterotrophic green alga in the family Chlorellaceae. It is known for its potential application in biofuel production. It was first characterized as a distinct algal species in 1965, and has since been regarded as a separate genus from Chlorella due its need for thiamine for growth. Auxenochlorella species have been found in a wide variety of environments from acidic volcanic soil in Italy to the sap of poplar trees in the forests of Germany. Its use in industrial processes has been studied, as the high lipid content of the alga during heterotrophic growth is promising for biodiesel; its use in wastewater treatment has been investigated, as well.

<span class="mw-page-title-main">Algae fuel</span> Use of algae as a source of energy-rich oils

Algae fuel, algal biofuel, or algal oil is an alternative to liquid fossil fuels that uses algae as its source of energy-rich oils. Also, algae fuels are an alternative to commonly known biofuel sources, such as corn and sugarcane. When made from seaweed (macroalgae) it can be known as seaweed fuel or seaweed oil.

<span class="mw-page-title-main">Phototrophic biofilm</span> Microbial communities including microorganisms which use light as their energy source

Phototrophic biofilms are microbial communities generally comprising both phototrophic microorganisms, which use light as their energy source, and chemoheterotrophs. Thick laminated multilayered phototrophic biofilms are usually referred to as microbial mats or phototrophic mats. These organisms, which can be prokaryotic or eukaryotic organisms like bacteria, cyanobacteria, fungi, and microalgae, make up diverse microbial communities that are affixed in a mucous matrix, or film. These biofilms occur on contact surfaces in a range of terrestrial and aquatic environments. The formation of biofilms is a complex process and is dependent upon the availability of light as well as the relationships between the microorganisms. Biofilms serve a variety of roles in aquatic, terrestrial, and extreme environments; these roles include functions which are both beneficial and detrimental to the environment. In addition to these natural roles, phototrophic biofilms have also been adapted for applications such as crop production and protection, bioremediation, and wastewater treatment.

<i>Nannochloropsis</i> Genus of algae

Nannochloropsis is a genus of algae comprising six known species. The genus in the current taxonomic classification was first termed by Hibberd (1981). The species have mostly been known from the marine environment but also occur in fresh and brackish water. All of the species are small, nonmotile spheres which do not express any distinct morphological features that can be distinguished by either light or electron microscopy. The characterisation is mostly done by rbcL gene and 18S rRNA sequence analysis.

<span class="mw-page-title-main">Algae bioreactor</span> Device used for cultivating micro or macro algae

An algae bioreactor is used for cultivating micro or macroalgae. Algae may be cultivated for the purposes of biomass production (as in a seaweed cultivator), wastewater treatment, CO2 fixation, or aquarium/pond filtration in the form of an algae scrubber. Algae bioreactors vary widely in design, falling broadly into two categories: open reactors and enclosed reactors. Open reactors are exposed to the atmosphere while enclosed reactors, also commonly called photobioreactors, are isolated to varying extents from the atmosphere. Specifically, algae bioreactors can be used to produce fuels such as biodiesel and bioethanol, to generate animal feed, or to reduce pollutants such as NOx and CO2 in flue gases of power plants. Fundamentally, this kind of bioreactor is based on the photosynthetic reaction, which is performed by the chlorophyll-containing algae itself using dissolved carbon dioxide and sunlight. The carbon dioxide is dispersed into the reactor fluid to make it accessible to the algae. The bioreactor has to be made out of transparent material.

Wageningen UR has constructed AlgaePARC at the Wageningen Campus. The goal of AlgaePARC is to fill the gap between fundamental research on algae and full-scale algae production facilities. This will be done by setting up flexible pilot scale facilities to perform applied research and obtain direct practical experience. It is a joined initiative of BioProcess Engineering and Food & Biobased Research of the Wageningen University.

Nasrin Moazami is an Iranian medical microbiologist and biotechnologist. She received her Ph.D. in 1976 from the Faculty of Medicine at Laval University. Moazami is the pioneer of biotechnology and microalgae-based fuels in Iran.

<i>Nannochloropsis</i> and biofuels

Nannochloropsis is a genus of alga within the heterokont line of eukaryotes, that is being investigated for biofuel production. One marine Nannochloropsis species has been shown to be suitable for algal biofuel production due to its ease of growth and high oil content, mainly unsaturated fatty acids and a significant percentage of palmitic acid. It also contains enough unsaturated fatty acid linolenic acid and polyunsaturated acid for a quality biodiesel.

<span class="mw-page-title-main">Culture of microalgae in hatcheries</span>

Microalgae or microscopic algae grow in either marine or freshwater systems. They are primary producers in the oceans that convert water and carbon dioxide to biomass and oxygen in the presence of sunlight.

Carbon-neutral fuel is fuel which produces no net-greenhouse gas emissions or carbon footprint. In practice, this usually means fuels that are made using carbon dioxide (CO2) as a feedstock. Proposed carbon-neutral fuels can broadly be grouped into synthetic fuels, which are made by chemically hydrogenating carbon dioxide, and biofuels, which are produced using natural CO2-consuming processes like photosynthesis.

<i>Chlorella sorokiniana</i> Species of green alga

Chlorella sorokiniana is a species of freshwater green microalga in the Division Chlorophyta. It has a characteristic emerald-green color and pleasant grass odor. Its cells divide rapidly to produce four new cells every 17 to 24 hours. The alga was described by Martinus W. Beijerinck in 1890. In 1951, the Rockefeller Foundation in collaboration with the Japanese Government and Hiroshi Tamiya developed the technology to grow, harvest and process Chlorella sorokiniana on a large, economically feasible scale. This microalga has also been used extensively as a model system to study enzymes involved in higher plant metabolism.

<i>Chlorella vulgaris</i> Species of green alga

Chlorella vulgaris is a species of green microalga in the division Chlorophyta. It is mainly used as a dietary supplement or protein-rich food additive in Japan.

<span class="mw-page-title-main">Carbon capture and utilization</span>

Carbon capture and utilization (CCU) is the process of capturing carbon dioxide (CO2) from industrial processes and transporting it via pipelines to where one intends to use it in industrial processes.

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