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Renewable and Sustainable Energy Reviews 115 (2019) 109371

Contents lists available at ScienceDirect

Renewable and Sustainable Energy Reviews


journal homepage: www.elsevier.com/locate/rser

Life cycle assessment, energy balance and sensitivity analysis of bioethanol T


production from microalgae in a tropical country
Nazia Hossaina,b,∗, Juliana Zainib, Teuku Meurah Indra Mahliac
a
Department of Civil and Infrastructure Engineering, School of Engineering, RMIT University, Melbourne, VIC, 3000, Australia
b
Faculty of Integrated Technologies, Universiti Brunei Darussalam, Jalan Tungku Link, Gadong, BE, 1410, Brunei Darussalam
c
School of Information, Systems and Modelling, Faculty of Engineering and Information Technology, University of Technology, Sydney, NSW, 2007, Australia

ARTICLE INFO ABSTRACT

Keywords: Overuse of petroleum and ongoing carbon-di-oxide (CO2) rise in the air of Brunei Darussalam has been emerged
Life cycle assessment as a major environmental concern in this country. To resolve this issue, a comprehensive life cycle assessment
CO2 emission (LCA) of alternative biofuel, bioethanol production from microalgae was demanded for realistic implementation.
Microalgae Therefore, LCA of bioethanol production from microalgae in terms of CO2 emission and energy balance was
Bioethanol
investigated based on the scenario of industrial-scale in Brunei Darussalam. This study demonstrated that 220
Energy balance
Water footprint
tons microalgae biomass was cultivated on 6 ha offshore lands for commercial bioethanol generation. The annual
outcome of this commercial bioethanol plant has revealed net CO2 balance 218.86 ton. From the energy per-
spective, this study manifested itself as favourable with net energy ratio, 0.45 and net energy balance,
−2749.6 GJ y−1. Apart from CO2 balance and energy generation aspect, the project demanded low water and
land footprints. For photobioreactor cultivation, water and land footprints were 2 m3 GJ−1 and 2 m2 GJ−1, re-
spectively as well as for open pond approach, they were 87 m3 GJ−1 and 13 m2 GJ−1, respectively. The project
also presented microalgae growth supplements (phosphorus and nitrogen) accumulation possibilities from
wastewater of manure and industries which is another positive aspect for benign environment. Overall, the
commercial plant presented low CO2 emission, low land and water demand for microalgae cultivation, alter-
native eco-friendly and cheaper nutrients sources, quite high energy generation with main product and by-
products. Thus, this study projected positive impact on energy and environmental aspects of microalgae-to-
bioethanol conversion.

1. Introduction minimizes CO2 in environment [6–10]. From few decades ago, various
biomass feedstock were being implemented as 1st and 2nd generation
Biofuel production from miscellaneous biomass sources has led to bioethanol sources since most of them interrupted human or animal
the rapid intensity of renewable energy generation in high demand of food-chain [7,11,12]. 1st generation bioethanol is extracted from food
worldwide energy [1–3]. Among biofuels, bioethanol highlighted itself substances e.g. palm oil, soybean oil, sorghum, sweet potato, sugarcane
due to clean combustion and reduction of greenhouse gas (GHG) and others. In the eve of enormous food scarcity in current world, 1st
especially CO2 emission to nature [4]. Bioethanol is being preferred generation bioethanol could not be stable in fuel market as it inter-
because of lower CO2 emission than conventional fossil fuel, oxygen rupted human food chain. 2nd generation bioethanol sources are agri-
release to the environment as well as absorption of substantial portion cultural residues, husk, straw, switchgrass, willow, sugarcane baggage
of CO2 emission by the energy crops and feedstock [5]; Usually fossil and others. They lost popularity due to high land area, water utilization
fuels contain finite sources and it is being depleted gradually. In this for ploughing energy crops for bioethanol instead of food crops and
case, bioethanol has been appeared as hope in energy domain since it is high pre-treatment cost. With these scenarios, 3rd generation bioe-
renewable, can be utilized by blending with fossil fuels with 5%–20% thanol grabbed strong appeal in the biofuel market due to enormous
(E5-E20) through new car models. Additionally, flexible fuel vehicles or bioethanol yield and positive environmental perspective [5,13,14].
dual-fuel vehicles can utilize bioethanol up to 85% besides petroleum. Among 3rd generation biomass for biofuels, microalgae, nitrite-oxi-
Hence it helps slowing down the fossil fuel depletion speed and dizing bacteria(NOB)-intensified biomass are being considered as new


Corresponding author. Department of Civil and Infrastructure Engineering, School of Engineering, RMIT University, Melbourne, VIC, 3000, Australia.
E-mail address: bristy808.nh@gmail.com (N. Hossain).

https://doi.org/10.1016/j.rser.2019.109371
Received 29 April 2019; Received in revised form 28 August 2019; Accepted 31 August 2019
Available online 10 September 2019
1364-0321/ © 2019 Elsevier Ltd. All rights reserved.
N. Hossain, et al. Renewable and Sustainable Energy Reviews 115 (2019) 109371

Nomenclatures LF Land Footprint, m2GJ−1


MW Molecular weight, kg
Symbols n Project life-time, year
NEB Net Energy Balance, GJ
BtOH Bioethanol, gallon NEin Net Energy input, GJ
Ein Energy input, MJ NER Net Energy Ratio,
Eout Energy out, MJ NPOP Net Primary O2 Productivity, kg
ED Electricity for Drying, MJ kg−1 OP Open Pond,
EE Electricity for Extraction, MJ kg−1 PBR Photobioreactor,
EO Energy for Others, MJ kg−1 RB Residual By-product, gallon
FDI Foreign Direct Investments, - SC Slurry Cake, kg
GHG Green House Gas, kg TCO2 Total CO2, kg
HD Heat for Drying, MJ kg−1 TN Total Nitrogen g
HE Heat for Extraction, MJ kg−1 TP Total Phosphorus, g
i, Project year, year WF Water Footprint, m3GJ−1
LCA Life Cycle Assessment, -

set of feedstock for carbon capturing from the environment as well as scalable form [20–22].
potential raw material for biofuel production [15,16]. With this cir- Life cycle assessment (LCA) of biofuel is being considered as an
cumstance, microalgae are considered as the most prominent feedstock integral conceptual issue prior to industrialization attempt due to se-
for 3rd generation bioethanol by rendering higher cellular carbohy- vere atmospheric pollution. LCA is to asses a product from raw material
drate content as well as not disturbing food or feed chain. Apart from processing to product utilization through all technological junctures
these, other merit of microalgae is that they are immune to every based on environmental and energy aspects [23]. With the current
weather and diverse water sources such as freshwater, seawater, was- study, the LCA of bioethanol commenced with raw material, main-
tewater) in traditional: open pond (OP) system and technologically tained microalgae processing and concluded with energy manufacture
advanced: photobioreactor (PBR) system with minimum water and land [18,24–28]. Since carbohydrate plays key vehicle role for bioethanol
utilization [17–19]. Moreover, microalgae have been chosen for bioe- production, it is vital to map carbohydrate enriched microalgae species
thanol over other biomass in Brunei Darussalam due to the faster such as Chlorella vulgaris (55%) for this LCA designed project. Chlorella
growth and higher amount of cellular carbohydrate. On the other hand, vulgaris is spherical shaped, single cellular (with nucleus) microalgae,
abundance of agricultural residues or other biomass for biofuel is also contains cellulose and hemicelluloses (carbohydrate components) in
not available in the country. Recently some research are ongoing on cell wall and starch is the main carbohydrate storage product. Chlorella
hardwood, Acacia species and other forms of bioenergy but still not in vulgaris utilizes sunlight, atmospheric CO2/wastewater CO2, H2O and

Rc.1. CO2-O2 balance in the microalgal-included environment. Where, RuBP=Ribulose 1,5-biphosphate, ATP= Adenosine Triphosphate, NADPH= Nicotinamide
Adenine Dinucleotide Phosphate, NADP+= Nicotinamide Adenine Dinucleotide Phosphate coenzyme as universal electron carrier, ADP= Adenosine Diphosphate,
Pi= inorganic phosphate, PS-I= Photosystem-1, PS-II= Photosystem-II.

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N. Hossain, et al. Renewable and Sustainable Energy Reviews 115 (2019) 109371

nutrients from growth medium and exhaled O2 to the environment. microalgae in order to clarify the net GHG minimization at the atmo-
Rc.1 presented the overall CO2–O2 balance via biofixation photo- sphere; to elucidate water footprint by microalgae cultivation in terms
synthesis process. Later on, microalgae accumulate carbohydrate due to of energy in order to lessen water contamination and pollution and
CO2 fixation during photosynthesis process shown in Rc.2. To enhance subside depletion of water sources; to measure the land footprint for the
bioethanol production from carbohydrate-based microalgae, it is im- sake of reducing of land usages by biofuel sector and expand space for
perative to outline the intracellular biological process, photosynthesis food crops for managing and maintenance of human and animal food
and manipulate the natural metabolisms to attain higher amount of chain; to distinguish the gross bulk of nutrients demanded for micro-
biomass via strategy like extra nutrient addition (Rc.2) [29]. algae cultivation, management of nutrients by utilizing diverse waste
sources instead of market supplementation that pinpoints economic
6CO2 + 12H2 O + Light + Nutrients C6 H12 O6 + 6O2 + 6H2 O (2) feasibility, soil and water amelioration and waste management; to
scrutinize the sensitivity of the key hypotheses for the process such as
In the raw material processing stage, microalgae maintain high CO2
the microalgae growth rate, CO2 and all other nutrient uptake as well as
uptake for carbohydrate production and liberate O2 free to the en-
O2 exhalation rate to figure the probable alternations.
vironment and in product life stage, bioethanol produces energy and
The aim of this study was to assess the potential environmental
sets CO2 free to the environment. Hence, via initial-to-final phases, CO2
footprints of microalgae bioethanol (alganol) production, evaluate en-
can be biologically recycled by the microalgae and that leads to CO2
ergy incorporation and elucidate the environmental and energetic
reduction in environment. Along with that, microalgae also contained
consequences by determining the suitable strategies from microalgae
large amount of carbohydrate for favourable bioethanol extraction.
cultivation to commercial bioethanol production associated with was-
Therefore, many countries (e.g. USA, Brazil, Argentina, India, Italy,
tewater utilization, barren offshore land and marine water use. Due to
Canada, China, Thailand, Japan and others) worldwide established
the favourable geographical location, plenty of seawater, adequate
mercantile microalgal bioethanol production plants [30]. Fig. 1 mapped
rainfall and sunlight all over the year in Brunei Darussalam, this re-
the industrialized regions for scaled-up bioethanol production. A study
search sought for the positive environmental and energetic attributes
revealed that USA, Brazil, European Union countries, China produce
for commercial bioethanol generation from mass microalgae cultiva-
14806, 7093, 1387, 813 million gallons, respectively in 2015 [30]. As a
tion. Therefore, this project aims to clarify the prospective environ-
result, the LCA configuration for bioethanol from microalgae was ap-
mental and energetic merits by implementing this approach in Brunei
peared as a crucial topic to be researched for the sake of healthy en-
Darussalam and other tropical regions.
vironment and eco-system. Hence, this environmental study was en-
The main scope of this research includes an alternative potential
tailed to design and inspect the environmental and energy impacts for
biofuel in the fuel market in Brunei Darussalam, useful utilization of the
projected plant venture [31–33].
offshore land and seawater as well as industrial wastewater accumu-
The objectives for this project include: to determine comprehensive
lation. Brunei Darussalam is one of the blessed countries for natural oil
technical-functional constituents of the bioethanol plant outline, assess
and gas resources worldwide. The use of petroleum and amount of CO2
the precise energy inputs and outputs, compute energy balance and
in environment is rocketing day by day and it has been appeared a
interpret the energy balance for this project was favourable or not to set
threat to the environment [34,35]. If this study can be conducted
up; to calculate GHG (CO2) emission by the product, CO2 uptake by

Fig. 1. Commercialization of bioethanol generation from microalgae worldwide.

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N. Hossain, et al. Renewable and Sustainable Energy Reviews 115 (2019) 109371

successfully in this country, fossil fuel can be blended with biofuel in and economic attributes. Then a plant scale beer column separates
mercantile approach that can be a new revolution for fuel market. In bioethanol, other liquid residual and slurry cake. Subsequently, pure
addition, the land beside sea in this country is either empty or full of bioethanol was recovered by dehydration through rectifier [30,43].
invasive plants and industrialization is not much established there yet.
This environment-friendly biofuel processing technology may en-
courage industrialization without damaging flora and fauna. On the 2.3. Data collection
other hand, if the use of wastewater from industries and manure can
contribute for biofuel production besides reduction of environmental Data collection is deemed as one of the most significant factors for
pollution, a new door will open for sustainable livestock farming in LCA. In this study, the input data, LCA planning and design were based
large scale and industries by maintaining healthy eco-system. on both national and international data resources of commercial mi-
The current study on life cycle assessment of microalgae-bioethanol croalgae cultivation and bioethanol production companies’ database
is a novel research study. To the author’ best knowledge, no research or and reports, related journal articles and technical datasheets, up-to-date
design study has been conducted yet on life cycle assessment of bioe- websites and articles for greenhouse gas emissions, total water and land
thanol from microalgae biomass so far. The closest related study was needed, nutrients uptake as well as researchers and experts on this
life cycle assessments of biofuels in China where status and challenges particular field. The operations and technologies in current process
of biofuels especially biodiesel have been reviewed, energy and GHG modelling was adopted by model microalgae cultivation design from
emission profile has been demonstrated. Besides, this study is a review the previous case study and cultivation technical set up in Brunei as
study and datasets from various research outcomes have been analysed well as integration with the microalgal biomass cultivation design and
[36]. Compared to that, the current study is a simulation-based research bioethanol production in Tuscany, Italy. The summary of microalgae-
study where large-scale plant set up has been designed with compre- bioethanol life cycle inventory for this study has been demonstrated in
hensive details of inventory, carbon emission, water and land footprints Table 1 [44,45].
and energy balance. Moreover, several life cycle assessments have been
performed on various culture methods of microalgae and extraction of
2.4. Selection of plant location
value-added products such as vitamins (e.g. β-carotene), proteins, bio-
oils and other biofuels (e.g. bio-diesel, biohydrogen, biomethane, bio-
The LCA modelling was projected for Brunei Darussalam on the
char) [37–40].
island of Borneo in Southeast Asia. The coastal area of Brunei
Darussalam was preferred as plant location since the cultivation water
2. Materials and methods
will be submerged from the sea. Besides that, coastal area also main-
tains suitable climatic condition and cheaper land. Brunei Darussalam
2.1. Materials
was in outlook for the bioethanol plant modelling from microalgae for
several aspects [45–48]. The reasons behind it were:
The potential microalgae candidate for this LCA study was Chlorella
vulgaris. These microalgae species contain carbohydrate content: 55%
(i) The tropical climate that is perfectly favourable for high rate of
and mainly consisted of two major components: celluloses in cell wall
microalgal growth
and starch in plastid. Cellulose and starch play as carbon sources during
(ii) Huge domain of coastal territory which is commendatory for
hydrolysis and fermentation for bioethanol production [41]. Previous
marine algae cultivation
studies have shown that Chlorella vulgaris contained 31.25% starch,
(iii) Bringing down the threatening intensity of CO2 from the en-
46.92% (w/w) cellulose and with simultaneous saccharification to
vironment
fermentation process, Chlorella vulgaris yielded 92.3% bioethanol [42].
(iv) Plenty of barren inexpensive coastal area to establish bioethanol
The main benefit of microalgae conversion to bioethanol is that the
plant
process can be approached with simultaneous saccharification (fer-
(v) The handiness of marine water
mentable sugar conversion) and fermentation (bioethanol production)
(vi) Direct sunlight throughout the whole year.
due to high cellulose and starch as well as zero lignin and low hemi-
celluloses containment [15,41].
A survey in Brunei reefs clarified that Brunei currently is experi-
encing a high rate of microalgal growth in coastal as well as escalating
2.2. Experimental methods
CO2 emission in the environment by highly fossil fuel usages
[47,49,50]. To diminish CO2 and induce bioenergy simultaneously,
Life cycle assessment from raw material to the market product of
wide-ranging bioethanol promotion plant from microalgae schemed in
this study consists of five major stages: microalgae cultivation and
Brunei Darussalam aspect.
harvesting, biomass pretreatment, extraction and fermentation, bioe-
thanol separation and bioethanol purification. Microalgae cell culturing
Table 1
from laboratory to plant scale, cell growth factors such as pH, culture
List of microalgae-bioethanol life-cycle inventory.
period, temperature, mixing, gaseous transfer monitoring, water, light,
carbon sources and nutrient supply are conducted in cultivation and Items Number of Items
harvesting stage. After certain culture period, settling biomass, shifting
Ponds 5
biomass from ponds/PBR from pre-treatment, wet pre-treatment, cell Photobioreactors (PBRs) 4
disruption and others are handled in pre-treatment stage. The main Mixers 9
phase of bioethanol production starts at extraction and fermentation Pumps (water, biomass collector, nutrients dosage, CO2 33
dosage, sludge cake collector)
stage where biomass extraction, hydrolysis with the presence of en-
Sensors (level, flow, temperature, pH, light, time) 54
zymes and supplements, fermentation in anaerobic condition take place Extractor 1
and raw bioethanol generates via this process. Microalgae extraction Fermenter 1
can be performed via various techniques such as ultra-sonication as- Rectifier 1
sisted, microwave assisted, solvent extraction, supercritical CO2, wet Beer Column 1
Evaporator 1
extraction and others. Microwave assisted extraction has been projected
Hydrolysis Tank 1
to be implemented in this study due to very less extraction time, Scrubber 1
minimum solvent usage, high extraction yield, positive environmental

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2.5. Assumptions treatments [52–54]. For this project, the liquid output excluding bioe-
thanol was considered as by-product for other biofuels raw material.
LCA estimation was considered as one of the most significant re- The last segment of the plant was bioethanol purification through de-
search areas to minimize CO2 GHGs from the environment before en- hydration process.
hancing bioethanol commercialization in Brunei Darussalam since the
country is well concerned about the green environment and balanced 2.7. LCA system boundary and limitations
eco-system. The comprehensive set of key estimations for this LCA
project substantiated in Table 2. For this project, two types of cultiva- A streamlined LCA was conducted following ISO 14044 guidelines
tion process were applied: photobioreactors and open ponds system [23]. Fig. 3 encompassed the LCA system boundary for this study. In
where PBR represented closed and monitored cultivation approach and Fig. 3, plain lined boxes represented all the inputs and outputs from
OP rendered the conventional microalgae culture. Both approaches microalgae to the final product and dashed lined boxes presented the
were handled concurrently, and biomass production rate is expected processing systems. LCA system boundary was emphasized on the
220 tons y−1 overall. overall carbon footprint (CO2 inhalation and O2 exhalation) through
the whole system from biomass cultivation to product utilization. It
2.6. Flow-sheeting for LCA approach and plant set-up aimed to simulate the exact impact of this project on the existing en-
vironment. Moreover, other LCA driving factors such as water footprint
An engineering system modelling of life cycle assessment of bioe- and land utilization were being concurrently focused on the project
thanol from microalgae in Brunei was implemented in this study in system modelling since reduction of water and land use for microalgae
terms of detailed energy balance, CO2–O2 balance, light and nutrients would play important role for greener environment besides minimizing
(TN & TP) utilization, water footprint and land-usage. The compre- greenhouse gas and energy balance [51]. The balancing simulations in
hensive process flow-sheeting has been diagrammed at Fig. 2. Fig. 2 this project were constructed theoretically due to the precise and well-
presented the overall process modelling incorporated the detailed en- established process view of CO2 capture from environment, CO2 uptake
ergy input-output through the process such as microalgae cultivation: to cultivate microalgae biomass and O2 give off to the environment.
open pond (OP) and photobioreactor (PBR), drying, extraction, hy- Therefore, it was expected that the system model can be projected by
drolysis, fermentation, separation (among product, by-products) and the balances shown in Fig. 3. Despite the overall process understanding,
purification (e.g. dehydration, evaporation) [11,30,31,33,51]. The still little variation might occur due to some factors like the overall
whole microalgae to bioethanol plant set up was planned to perform as cultivation environment, the growth rate of microalgae, nutrients, light
multi-functional system which included main product: bioethanol and CO2 utilization efficiency by microalgae species [18,55–57].
generation and purification both as well as it separated residual bio- The aim of this project was to evaluate environmental impacts of
mass (liquid) and slurry cake. The plant design comprised of four main microalgae-bioethanol production in Brunei Darussalam in terms of
sectors: (i) microalgae cultivation, (ii) microalgae-bioethanol conver- carbon, water and land footprint as well as nutrients uptake for 20 years
sion, (iii) bioethanol purification and (iv) separation between residual life-time. Other specifications of the overall project from plant set-up to
biomass (liquid) and slurry cake. Microalgae cultivation sector con- marketing and life cycle cost analysis have been demonstrated elabo-
tained 2 different approaches: open pond and photobioreactor. The rately in Part-1 of this project and published as journal article named
microalgae-bioethanol conversion was consisted of several steps such as ‘Techno-economic and sensitivity analysis of microalgae as commercial
biomass drying, extracting the metabolites from cells, simultaneous feedstock for bioethanol production’. According to the techno-economic
saccharification (hydrolysis) and fermentation through enzymatic re- analysis of the study, commercial bioethanol production from micro-
actions and separation. While microalgae biomass was processed algae in Brunei Darussalam was successful and favourable economically
through saccharification, total carbohydrate content (total sugar) was [30]. Hence, this LCA system boundary excluded those materials and
divided into two types of sugars: fermentable and unfermentable su- technical attributes what have been discussed comprehensively in
gars. Fermentable sugars were fermented and bioethanol has been techno-economic analysis.
produced as main product of the project where unfermented sugars This LCA system boundary excluded:
remained as by-product [52]. Apart from unfermentable sugars, other
cellular contents such as lipid, protein and other metabolites were left - Technological simulations and advancements (e.g. recycling system
as residual by-products (liquid). Fig. 2 diagrammed conversion process of water and nutrients)
from microalgae to products and by-products in brief. Separation pro- - The total number of specific equipment such as reactor, pumps,
cess of bioethanol has been designed through beer column, type of sensors and others, equipment specifications and microalgae-culti-
rectifier column that separated bioethanol, residual by-products (li- vation system elaboration.
quid) and slurry cake. The system only maintained saccharification and - The logistics and transportation systems related plant equipment
fermentation before separation between products and by-products. and plant set-up tools to the specific plant location, raw materials,
Thus no interruption has been occurred to produce bioethanol with fast nutrients (TP, TN) for microalgae growth and harvesting, the final
process. The residual by-product usually contains cellular lipid, protein product (bioethanol) and co-products were not discussed in this
and other metabolites and this residual by-product can be source of study.
other biofuels raw material in further such as biodiesel (methyl ester), - Capital investment details such as purchased and delivered equip-
biomethane, biohydrogen, glycerol carbonate and others with different ments and installation, instrumentation controls, piping, electrical

Table 2
Key estimations for microalgae cultivation and bioethanol production [44,45,91,92].
Key Items Photobioreactors (PBR) Ponds

−1 −1
Microalgal Biomass Productivity 56 tons ha y 28 tons ha−1 y−1
Total Biomass Production 110 tons y−1 or 100, 000 kg y−1 110 tons y−1 or 100,000 kg y−1
Cultivation Area (ha) 2 ha 3.94 ha
Cultivation system geometry (Single Unit) 130 aligned tube/per unit, 75 tubes, tube diameter 0.05 m 975 m2 per ponds, width 10 m, length 85 m, depth 0.30 m
Bioethanol yield 58.90 m3 ha−1 y−1 24.94 m3 ha−1 y−1
Total Bioethanol Production 31, 119.49 gallons y−1 25, 968.13 gallons y−1

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Fig. 2. Process flow of overall LCA methodology.

system, buildings and service facilities, engineering and supervision, 2.8. Calculating methods
operation and maintenance.
- Life cycle cost analysis including plant establishment and service, 2.8.1. Net primary O2 productivity (NPOP) and CO2 balance
raw material production cost, selling prices of products and by- NPOP in this study was computed theoretically through dividing
products. molecular weight of O2 (32 g) by the molecular weight of CO2 (44 g)

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Fig. 3. LCA system boundary of microalgae-to-bioethanol.

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N. Hossain, et al. Renewable and Sustainable Energy Reviews 115 (2019) 109371

and later multiplying the ratio with total CO2 consumption during footprints of this study were calculated based on the well-established
microalgae cultivation period (Eq. (1)). NPOP rate is directly correlated footprint methods of crops and derived crop products conducted by
with CO2 uptake by algal biomass. NPOP is important to be calculated Mekonnen and Hoekstra [63]. Eqs. (7) and (8) were used to clarify
for determining O2–CO2 balance by the photosynthesis system of mi- water footprint for both PBR and OP system. Harvesting index in Eq. (7)
croalgae (Rc. 2.) since CO2 is a greenhouse gas that absorbs and emits presented the ratio of total microalgae production yield (with water) by
radiation within the thermal infrared range in atmosphere where O2 total microalgae dry biomass yield. The weight fraction of microalgae
does not absorb and emit radiation as well as its essential gas element residue (Eq. (8)) rendered the ratio of bioethanol output to total output
for the existence of human, animal and other living beings [58]. The products. Thermal and electrical efficiency is usually conditional on the
NPOP and CO2 balancing of this study was calculated based on the system. With most of industrial scale scenarios, the conversion effi-
method of net primary productivity (NPP) and carbon storage data ciency is similar [64].
analysis [59]. Data for CO2 consumption during microalgae cultivation
WFTotal Biomass Yield = WFBiomass Yield per unit × Harvesting Index (7)
(per kg dry biomass) and CO2 emission by bioethanol (per gallon) were
calculated based on different industrial survey reports and previous
WFEnergy
research findings associated with carbon stock studies, total CO2 con-
sumption by annual biomass production and CO2 emission by bioe- WFTotal Biomass Yield × Weight fraction of microalgae residue × 1000
=
thanol from this project. High Heating value of bioethanol, ( 29.7MJ
kg ) × Thermal &
MW of O2
NPOP = × Total CO2 consumption Electrical conversion efficiency
MW of CO2 (1)
(8)
3 −1
where, WF= Water Footprint (m GJ ).
2.8.2. Energy balance methods Land footprint or land usage for bioethanol production from mi-
Energy balance drives the most significant role in the modular croalgae depicted the required land or areas to cultivate microalgae
system engineering of industrial scale to regulate the LCA of the project biomass for the generation of the projected amount of bioethanol in
[60]. In this study, input and output energy investment were identified terms of energy [65,66]. Eq. (9) illustrated the land footprint de-
based on heat and electricity demand and manufacture. Energy input termination method [67].
defined the total energy through electricity and heat for drying mi-
croalgae biomass, extraction of biomass and other distributed energy Total Microalgal Biomass Production
LFEnergy =
throughout the whole system from cultivation to bioethanol purifica- Biomass yield × Required energy for conversion process (9)
tion [55]. Output energy was mainly calculated as energy produced by
where, LF = Land Footprint (m2 GJ−1).
the main product, bioethanol. Net energy input consists of energy
The most prior nutrients at the cultivation stage for the microalgae
(excluded energy credits) generated from by-products. Net energy
life cycle assessment were total phosphorus (TP) and total nitrogen
balance equated the energy balance between net energy input and total
(TN) [26]. TN and TP per unit biomass data were gathered from pre-
energy output. Net energy ratio scaled energy impact on process system
vious industrial approaches and the annum and project life-time nu-
which is the ratio of net energy input and total energy output. Ac-
trient requirements were simulated. Other major nutrient requirement
cording to previous LCA analyses, lesser number of ratio indicated the
was light where sunlight and UV light (generated by using electricity
greater energy effectiveness on the process [6,51,61]. Eqs. (2)–(6) were
which was included in energy balance) were the light sources for OP
driven to assess the energy input, energy output, net energy input, net
and PBR, respectively [26,68].
energy balance, net energy ratio of this project, respectively.
n
Ein = EED + EHD + EHE + EEE + EEO 2.9. Sensitivity analysis
i=1 (2)
Sensitivity analysis was conducted for this project to identify the
Eout = EBtOH (3) influential variability. Since in industrial scale, theoretical calculations
n n n might not be precise for different scenarios, so sensitivity analysis has
NEin = Ein ERB ESC been performed. The projection may vary and for such case, sensitivity
i=1 i=1 i=1 (4) analysis usually determines the most probable possibilities
n n [30,51,69,70]. For this study, the sensitivity factors included micro-
NEB = NEin Eout algae growth rate, carbohydrate content (key vehicle to produce bioe-
i=1 i=1 (5) thanol from microalgae), nutrients (TP, TN), water, total carbon-di-
oxide (TCO2) and NPOP. The analysis data were simulated from the
NEin
NER = study and compared with the previous industrial application-based
Eout (6) framework. Two different datasets were used for uncertain scenarios
where, Ein = Energy input (MJ), EED = Energy consumed by Electricity and they were compared with the studied scenario. Microsoft excel has
for Drying (MJ kg−1), EHD = Energy consumed by Heat for Drying (MJ been used to demonstrate the comparison with uncertainties and the
kg−1), EHE = Energy consumed by Heat for Extraction (MJ kg−1), outcome has been showcased in graphical representation.
EEE = Energy consumed by Electricity for Extraction (MJ kg−1),
EEO = Energy consumed by Others (MJ kg−1), Eout = Energy out (MJ), 3. Results and discussion
EBtOH = Energy generated by Bioethanol (MJ), NEin = Net Energy
input, ERB = Energy generated by Residual By-product (liquid) (MJ), The detailed cultivation system geometry for each unit was designed
ESC = Energy generated by Slurry Cake (MJ), NEB= Net Energy Bal- and bioethanol yield over the year was schemed based on previous
ance, Eout = Energy Output (MJ), NER=Net Energy Ratio. research studies in Table 2. To attain similar biomass amount from both
OP and PBR strategies, OP required double cultivation area compared
2.8.3. Water footprint, land footprint and total nutrients to PBR because PBR maintained controlled growth rate that ensure
Water footprint was assessed in this study to determine the water consistent and large amount of cell density in smaller cultivation area
consumption for bioethanol production from microalgae in terms of while OP has uncontrolled growth rate. Therefore, PBR maintained
heat and electrical conversion efficiency [26,62]. The water and land gross biomass productivity, 58.90 m3 ha−1 y−1 that depicts twice

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N. Hossain, et al. Renewable and Sustainable Energy Reviews 115 (2019) 109371

higher yield than OP, 24.94 m3 ha−1 y−1, yet OP was mapped to ex- as well as diminish atmospheric GHG [73,76,77].
periment due to reducing the cost for PBR set up and maintenance
expenses. The schematic of microalgal growth vs bioethanol production 3.3. CO2 balance and net primary O2 productivity
for both OP and PBR has been diagrammed at Fig. 4. Techno-economic
analysis of this study presented that PBR and OP construction expense The relationship between CO2 gas emission by bioethanol and GHG
was 102,000 US$ and 20,000 US$, respectively. That revealed PBR consumption by microalgae is a consequential factor for LCA [78].
demands approximately five times higher expense than OP set up [30]. Table 6 reported that 1 kg microalgae dry biomass consumed 1.83 kg
Table 3 demonstrated the yearly gross output rate. CO2 where 1 gallon bioethanol produced 2.59 kg CO2. As a result, net
CO2 balance was 218.86 tons per year. In comparison with conven-
3.1. Water and land footprint tional fossil fuel, net CO2 production from this project was much lesser.
For instance, 1 gallon pure ethanol produces 5.77 kg CO2 that is 3.18 kg
According to the water footprint concept of Hoekstra, water foot- higher than CO2 emitted from bioethanol combustion. Additionally,
print is a signal for water use in relation to consumer products such as conventional fuels such as 10% fuel ethanol (E10), pure gasoline (fossil
agricultural, industrial products. Like other footprints (e.g. carbon, fuel) and diesel (fossil fuel) produce 8.01 kg, 8.90 kg and 10.15 kg CO2,
energy footprint), water footprint is one of the crucial aspects behind respectively. Therefore, these outcomes proved that bioethanol emitted
benign environment [71]. Table 4 demonstrated that the WF for bioe- the minimum GHG gas to the environment. Furthermore, in comparison
thanol production from microalgae was 2 m3 GJ−1 and 87 m3 GJ−1 for with other biofuels such as 100% biodiesel (B100), bioethanol pro-
PBR and OP approach, respectively. Microalgae demanded very lower duced almost 4 times lower CO2 gas since B100 emitted 9.42 kg CO2
WF via both cultivation strategies in comparison with other energy [79]. These findings determined that bioethanol caused the least CO2
crops such as sugarcane, cassava, sorghum biomass shown in Fig. 5. WF emission and even the conventional fuel blended with bioethanol re-
associated with OP cultivation was still premier than PBR since the OP duced the CO2 emission. Bioethanol generation and its’ application in
system with traditional pond culture in an open environment sustaining energy sectors are much more favourable than fossil fuels even other
natural microalgal growth and water surface suspension, unlike PBR. biofuels [6,11]. Other than CO2 emission minimization, microalgae
Moreover, WF study by Hoekstra also demonstrated that crop produc- produced high amount of O2, 1.33 kg O2 kg−1 dry biomass which is
tion consumed the largest global water footprint where green (rain- beneficial for the survival of human, animal and other living beings
water), blue (surface water), grey water (wastewater) have been used except plants, as well as O2, does not act as greenhouse gas by emitting
with 5771 Gm3/y, 899 Gm3/y and 733 Gm3/y, respectively. The ad- or absorbing radiation from atmosphere [11].
vantage of microalgae production is that microalgae biomass can be
cultivated with any these 3 types of water. Usage of greywater for this
3.4. Energy balance analysis
purpose may save more green and blue water for other crop cultivation
which is needed to stabilize food and feed chain [72]. Along with that,
Another crucial component of this project was energy balance
one of the vital facts of WF consumed by microalgae is to re-use the
analysis. In this study, Table 7 and Table 8 delineated energy input-
water for next batch of microalgae cultivation or other essential needs.
output per unit, energy balances for the bioethanol production from
WF is a significant concept for this LCA study in Brunei Darussalam
microalgae on an annual basis and project-lifetime, respectively. In
since the total WF in this country is already high and it is in range with
both of these tables, overall energy input-output was showcased instead
2000–2500 m3/y per capita based on Hoekstra WF analysis [72]. Be-
of different cultivation system basis. Cultivation system demands
sides low WF, microalgae simultaneously proved low LF or land utili-
comparatively less energy investment than drying and extraction pro-
zation and it was only 2 m2 GJ−1 and 13 m2 GJ−1 for PBR and OP
cesses. PBR cultivation requires much more energy consumption than
system, respectively. LF for microalgae appeared as the least among
OP system due to the extra-demand of artificial light (UV light) and
most popular energy crops such as corn grain, sugarcane, cassava,
heat in closed system. Both processes have energy dependency for
sorghum, and jatropa [26,33,64,67,73].
running mixers, pumps and sensors for water and nutrients supply,
mixing and gaseous transfer during cultivation [30]. Based on the da-
3.2. Total nitrogen (TN) and total phosphorus (TP) utilization
taset, required energy for both of these cultivations was approximately
0.7 kg−1 which was expressed as required energy for others. According
Nutrients play a remarkable role in enhancing microalgal growth.
to Table 7, among input energy investment, biomass drying by heat
Nitrogen and phosphorus were listed on top as macronutrients de-
contained the highest energy requirement, 16.48 MJ kg−1 [55,56].
manded rapid growth kinetics. Potassium, magnesium, sulphur and
Usually well-dried biomass is capable of producing more purified and
others were implemented in minor amounts as micronutrients [26]. For
higher quality of biofuel products. The alternative process to dry the
this study, 52.5 g nitrogen and 18.9 g phosphorus were used shown at
biomass can be solar drying which is well-established approach among
Table 5 to produce 1 kg microalgae dry biomass [55,74]. Based on an
experimental study, whole harvesting water was recycled to be utilized
for microalgal growth of next batch and a significant amount of nu-
trients was recovered from recycled this water which was equal to 55%
of total nutrients for next batch microalgae harvesting [26]. Therefore,
application of recycled water for microalgal growth medium is pro-
jected to minimize additional investment for nutrients. Moreover, if the
wastewater from animal farming or industries can be integrated with
the microalgae production plant, the investment of added nutrients
could be eliminated thoroughly [75]. Fig. 6 illustrated the nutrients
utilization (TN and TP) by microalgae from waste while Fig. 6(a) and
(b) represented for manure and industrial wastewater, respectively.
Wastewater is enriched with heterogeneous organic and inorganic nu-
trients (including TN and TP) to stimulate the microalgal growth ki-
netics. Wastewater application as growth supplements influenced the
plant design in two important prospective: economic and environ- Fig. 4. Schematic of microalgal growth vs bioethanol yield for both cultivation
mental by using the inorganic waste to produce value-added products systems.

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N. Hossain, et al. Renewable and Sustainable Energy Reviews 115 (2019) 109371

Table 3
Output items with simulated gross production rate.
Output Items Simulated Gross Production

Main Product, Bioethanol 57087.5805 gallons y−1


Residual By-product (liquid) for other biofuel raw 10000 gallons y−1
material
By-product, Slurry Cake 8000 kg y−1

Table 4
Water footprint and land footprint of different bioethanol sources.
Energy Crops/Sources Water Footprint (m3 GJ−1) Land Footprint (m2 GJ−1)

Microalgae (PBR) 2 2
Microalgae (OP) 87 13

Fig. 6. (a). Nutrient utilization by microalgae from manure (animal hus-


bandry). (b). Nutrient utilization by microalgae from industrial wastewater
[76,77].

Fig. 5. Microalgae water and land footprint comparison with other popular
energy crops for bioethanol production [14,96]. 3.5. Sensitivity analysis

In this project, a sensitivity analysis was performed based on the key


Asian countries to process microalgae for food-quality and agricultural
assumptions of nutrients input for microalgae growth, growth rate,
purpose. Albeit, sun-drying process cannot be optimized for commercial
carbohydrate enrichment and CO2–O2 balance. Previously different
application since sunlight is nature-regulated approach and cannot be
research studies presented different nutrients input, growth rate of
controlled per demand especially in cold weather [80]. Consequently,
microalgae biomass, carbohydrate amount (main component for bioe-
energy produced by electricity and heat were applied on the current
thanol) and GHG (CO2) generation [24–26,41,55,81–83]. This study
study to dry the biomass, extract bioethanol and other value-added
conducted sensitivity analysis by considering the previous results from
products as well as run the operating systems from cultivation to pur-
minimum to maximum range for each factor to project the highest to
ification of the product [56].
lowest outcome of this plant design. The all key parameters in this
Table 8 outlined the energy balances of the overall project based on
sensitivity analysis were compared with the average inputs and outputs
year and project lifetime. Net energy input covered the energy input of
of both PBR and OP system of the microalgae bioethanol plant.
the project (excluding energy credits) by by-products. The negative
Table 9 mentioned the specific numbers of the key factors used for
number of the net energy balance manifested that the energy produc-
the current study as well as different uncertain scenarios experimented
tion from the project was superior than the energy investment and that
on commercial applications worldwide [55,75]. Sensitivity analysis in
meant absolute favour for the project scheme [6,11]. Net energy ratio
Fig. 8 was projected on the basis of some parameters related to mi-
reflects an energetic impact barometer on the overall process energy
croalgae culture, nutrient consumption variation, CO2 utilization dif-
input. NER less than 1 is desirable for any system to be optimized.
ference, lack of stability in growth rate and intracellular conversion
Table 8 reported that NER for this study is 0.45, thereby it can be
process, the variation of carbohydrate containment what might cause
summarized that energy effectiveness was appropriately fitted for this
uncertainty on the project outcome [84]. The maximum and minimum
project [51]. Net energy input and output scenario were diagrammed in
range of total CO2 and NPOP in this sensitivity analysis did not vary
Fig. 7.
much while a little high variation was shown with Chlorella vulgaris
microalgae growth rate, water and nutrients (TP and TN) and

Table 5
TN and TP assessment.
Nutrient Consumption Amount (g) required to produce per kg microalgae dry Amount required per year (ton Amount required for project life-span (ton
biomass y−1) life-span−1)

TN 52.5 11.58 231.48


TP 18.9 4.17 83.34

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N. Hossain, et al. Renewable and Sustainable Energy Reviews 115 (2019) 109371

Table 6
Life cycle assessment (LCA) simulations on environmental factor CO2 (GHG) and NPOP.
CO2 Usage CO2 Amount(kg) References

CO2 consumption for microalgae dry biomass production per kg 1.83333 [73,75,93]
CO2 consumption for annual biomass production (200000 kg) 366666 (366.666 ton) Calculated
CO2 emission by bioethanol per gallon 2.59 [93,94]
CO2 emission by annual bioethanol produced by the plant (57087.58 gallon) 147800 (147.800 ton) Calculated
Annual Net CO2 Balance 218866 (218.866 ton) Calculated
Net CO2 Balance through plant life-span (20 years) 4377320 (4377.32 ton) Calculated
NPOP per kg microalgae biomass 1.33 Calculated
NPOP for annual biomass (200,000 kg) 266660 (266.660 ton) Calculated
NPOP for plant life-span (20 years) 5333200 (5333.2 ton) Calculated

Table 7 3.5.1. Limitations of sensitivity analysis


Energy input-output per unit. The current sensitivity analysis shown in Fig. 8 was performed
Energy items MJ References
based on the previous experimental dataset. The uncertainties of mi-
croalgal growth rate and carbohydrate content may influence the
Required Electricity for Drying (ERD) 1.23 kg−1 [55] amount of desired bioethanol as well as net bioethanol production per
Required Heat for Drying (EHD) 16.48 kg−1 [55] year. Uncertainties of water consumption for microalgae cultivation
Required Heat for Extraction (EHE) 0.04 kg−1 [55]
Required Electricity for Extraction (EEE) 0.66 kg−1 [55]
may affect the water footprint and energy balance involved with the
Required Energy for Others (EEO) 0.7 kg−1 [55,80] pumping system. Variation in total phosphorus and total nitrogen
Generated energy by main Bioethanol (EBtOH) 89 gallon−1 [95] usages may have impact on both economic and environmental aspects
Generated energy by Residual By-product (liquid), 129 gallon−1 [95] since this study suggested manure and wastewater utilization for mi-
(ERB)
croalgae cultivation. Additional demand of nutrients may cause new
Generated energy by by-product, Slurry Cake (ESC) 25.1 kg−1 [61]
investment in purchasing extra TP and TN. Differences in total CO2
accumulation and net primary O2 productivity can impact on en-
Table 8 vironmental CO2–O2 balance. To demonstrate this point of view, if this
Energy balance calculations. process accumulates less amount of CO2 than expected, the projected
years for CO2 reduction will be prolonged. Another major constraint of
Energy Items GJ y−1 GJ life-time−1
this study was that the sensitivity analysis was not conducted separately
Total Energy Input (Ein) 3822 76440 for OP and PBR cultivation approaches. Moreover, due to the priority of
Energy generation by Residual By-product (liquid), 1290 25800 environmental issues, only microalgae biomass production was em-
(ERB) phasized for this sensitivity analysis while uncertainties related to pre-
Energy generation by by-product, Slurry Cake (ESC) 200.8 4016
treatment methods and conversion technologies were not considered.
Total Energy Output (Eout) 5080.78 101616
Net Energy Input (NEin) 2331.2 46624
Net Energy Balance (NEB) −2749.6 −54992
Net Energy Ratio (NER) 0.45 0.45 3.6. Practical implications, policy, challenges and recommendations

According to the report of MC Biotech, a subsidiary of Mitsubishi


carbohydrate contents. Chlorella vulgaris growth rate maintained var- Corporation and Nissui, Brunei Darussalam has a very favourable en-
iation due to the different cultivation location and growth conditions vironment, air quality and water quality for commercial microalgae
that drives the difference on water and nutrient demand and results production in large scale. Due to these facilities, MC Biotech has been
different carbohydrate content for different studies [83]. officially launched by the Ministry of Energy and Industry in colla-
boration with Japan at Bio-innovation Corridor in Kampong Tungku at
2016. Total 20 million Brunei Dollar has been invested in this industrial

Fig. 7. Energy balance scenario of bioethanol production from microalgae.

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N. Hossain, et al. Renewable and Sustainable Energy Reviews 115 (2019) 109371

Table 9
Key parameters for sensitivity analysis and different scenarios related to microalgae cultivation (per kg).
Key Parameters for Sensitivity Analysis Current Study Uncertain Scenario 1 (Minimum values) Uncertain Scenario 2 (Maximum values)

−1
TCO2 content (kg biomass ) 1.83 1.63 1.96
NPOP (kg biomass−1) 1.33 1.18 1.42
TN content (g kg biomass−1) 52.5 17.5 72.5
TP content (g kg biomass−1) 18.9 12.9 22.7
Make-up water (L kg biomass−1) 373 239 413
Carbohydrate Content (% w/w) 41 35 52
Growth rate (g m−2 d−1) 25 16 36

microalgae production plant and the yearly biomass output 18 metric outlook while the total production cost was US$ 2.22 million per
ton as raw material for astaxanthin (β-carotene), a dietary supplement annum, total bioethanol selling price was US$ 2.87 million/annum and
production [85]. The government of Brunei Darussalam also exempted total by-product selling cost was US$1.6 million/annum. Even with the
income tax for 11 years for the commercial biotech company as well as sensitivity analysis based on various growth rate, water demand, total
import duties which causes plenty of costs. Besides that, ministry of nutrients utilization, CO2 production of similar ranges with this study,
energy and industry also invited foreign direct investments (FDIs) TEA simulation still presented a positive impact economically [30].
stating that “What we really need are FDIs, which are able to create Therefore, this LCA has been conducted to evaluate the environmental
value-added products and services in Brunei Darussalam, and to colla- attributes for realistic justification of commercial microalgae-bioe-
borate together with the government agencies and local micro, small thanol plant establishment in the country.
and medium enterprises (MSMEs). We invite FDIs from across the Among main sectors of the total system: (i) microalgae cultivation,
supply chain to allow the development of robust in-country value (ii) microalgae-bioethanol conversion and (iii) bioethanol purification,
chains and industrial ecosystems. We need FDIs to be able to work bioethanol purification is the hotspot of the process since purified
further downstream to ensure that most of the bioprocessing is carried bioethanol is the main product to be generated as the alternative fuel
out in Brunei Darussalam. This can, in turn, create and generate capital, source which is considered as major contributor to green energy.
spin-offs in the local market, employment opportunities, and ulti- Bioethanol applications as transportation fuel not only contributed to
mately, diversify and boost the Brunei economy” [86]. Therefore, the the energy sector but also minimized the greenhouse gas emission.
application of current study is being encouraged to be implemented Besides, the cultivation process also played important role to impact
with any non-government or individual organization with the colla- positively on environment by absorbing CO2 for biomass growth and
boration of government agencies. produce O2. Apart from the CO2 mitigation, microalgae cultivation used
Another recent news of 2018 presented that the first milestone set comparatively low amount of water and land than other terrestrial
by Government of Brunei Darussalam to diversify its power generation crops for biofuel purposes as well as microalgae accumulated pollu-
mix with renewable energies. The aim is to produce 954 GW of re- tants: nitrogen and phosphorus from wastewater for nutritional demand
newable energy or 10% of total energy for power generation mix by — this application purified wastewater which is also environmentally
2035. Commercial bioethanol production from microalgae could be a benign.
remarkable option for this agenda. According to the International Though the first part of this project presented economically benefits
Energy Agency, in 2014, Brunei Darussalam initiated national policy and current study manifested environmental merits, the study still
‘Energy White Paper’ declared power generation from renewables with contains some challenges and that is to be researched further:
both small and large scale. This policy prioritized lower CO2 emission
and turning down of environment temperature, renewable energy - This study considered the energy involvement and environmental
policy and regulatory frameworks, scale-up market deployment, raise impacts of the initial plant set up with regular biomass productivity
awareness and promote human capacity development, support re- of Chlorella vulgaris species. To achieve higher cell densities, addi-
search, development, demonstration and technology transfer [87,88]. tional CO2 requirement, CO2 sources, required energy for that's,
This policy encouraged our study to be implemented as a real appli- further CO2 emission profile impact have not analysed in this study.
cation in Brunei Darussalam. Industrial emission of CO2 utilization in algae cultivation is re-
Techno-economical assessment (TEA) of bioethanol commerciali- commended to be analysed further.
zation from Chlorella vulgaris in Brunei Darussalam indicated profitable - For higher microalgae biomass yield besides wastewater

Fig. 8. Sensitivity analysis for microalgae biomass production [24–26,41,55,81–83].

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N. Hossain, et al. Renewable and Sustainable Energy Reviews 115 (2019) 109371

management, this study emphasized on manure and industrial Appendix A. Supplementary data
wastewater application during cultivation and harvesting stage.
Wastewater contains various nutrients that help cell growth and Supplementary data to this article can be found online at https://
minimizes the cost of extra supplements (chemicals). Besides, mi- doi.org/10.1016/j.rser.2019.109371.
croalgae can survive in polluted even toxic environment [89]. Since
this study was projected for mercantile microalgae cultivation for References
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