Photobioreactor

A photobioreactor is a bioreactor that utilizes a light source to

cultivate phototrophic microorganisms.[1] These organisms use photosynthesis to generate biomass
from light and carbon dioxide and include plants, mosses,
macroalgae, microalgae, cyanobacteria and purple bacteria. Within the artificial environment of a
photobioreactor, specific conditions are carefully controlled for respective species. Thus, a
photobioreactor allows much higher growth rates and purity levels than anywhere in nature or
habitats similar to nature. Hypothetically, phototropic biomass could be derived from nutrient-rich
wastewater and flue gas carbon dioxide in a photobioreactor.

Moss photobioreactor to cultivatemosses like Physcomitrella patens at laboratory scales

Open raceway pond

Contents
[hide]

Open systems[edit]
The first approach for the controlled production of phototrophic organisms was and still is a
natural open pond or artificialraceway 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 liquids surface. This construction principle is the simplest way of production for
phototrophic organisms. But due to their depth (up to 0.3 m) and the related reduced average light
supply, open systems only reach limited areal productivity rates. In addition, the consumption of
energy is relatively high, as high amounts of water containing low product concentration have to be
processed. Open space is expensive in areas with a dense population, while water is rare in others.
Using open technologies causes high losses of water due to evaporation into the atmosphere.

Closed systems[edit]

Since the 1950s several approaches have been conducted to develop closed systems, which
theoretically provide higher cell densities of phototrophic organisms and therefore a lower demand of
water to be pumped than open systems. In addition, closed construction avoids system-related water
losses and the risk of contamination through landing water birds or dust is minimized.[2] 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. Many
different systems have been tested, but only a few approaches were able to perform at an industrial
scale.[3]

Redesigned laboratory fermenters[edit]

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.[4] 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[edit]

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 CO2. Tubular photobioreactors are established worldwide from
laboratory up to production scale, e.g. for the production of the carotenoidAstaxanthine from the
green algae Haematococcus pluvialis or for the production of food supplement from the green
algaeChlorella 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. 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.[5]
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 a laboratory research scale. Being controlled by a complex process control system
the regulation of the environmental conditions reaches a high level.[6]

Christmas tree photobioreactor[edit]

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.[7] 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
preventbiofouling and ensure high final biomass concentrations. The combination of turbulence and
the closed concept should allow a clean operation and a high operational availability.[8]

Plate photobioreactor[edit]

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.[9]
In April 2013, the IBA in Hamburg, Germany, a building with an integrated glass plate
photobioreactor facade, was commissioned.[10]

Horizontal photobioreactor[edit]

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[edit]
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.[11]

Outlook[edit]
The discussion around microalgae and their potentials in carbon dioxide sequestration and biofuel
production has caused high pressure on developers and manufacturers of
photobioreactors.[12] 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.