Key Targets for Improving Algal Biofuel Production

Chapter 19 - Scale-up and commercialization of algal cultivation and biofuels production

BackgroundMicroalgae are touted as an attractive alternative to traditional forms of biomass for biofuel production, due to high productivity, ability to be cultivated on marginal lands, and potential to utilize carbon dioxide (CO2) from industrial flue gas. This work examines the fossil energy return on investment (EROIfossil), greenhouse gas (GHG) emissions, and direct Water Demands (WD) of producing dried algal biomass through the cultivation of microalgae in Open Raceway Ponds (ORP) for 21 geographic locations in the contiguous United States (U.S.). For each location, comprehensive life cycle assessment (LCA) is performed for multiple microalgal biomass production pathways, consisting of a combination of cultivation and harvesting options.ResultsResults indicate that the EROIfossil for microalgae biomass vary from 0.38 to 1.08 with life cycle GHG emissions of −46.2 to 48.9 (g CO2 eq/MJ-biomass) and direct WDs of 20.8 to 38.8 (Liters/MJ-biomass) over the range of scenarios analyzed. Further anaylsis reveals that the EROIfossil for production pathways is relatively location invariant, and that algae’s life cycle energy balance and GHG impacts are highly dependent on cultivation and harvesting parameters. Contrarily, algae’s direct water demands were found to be highly sensitive to geographic location, and thus may be a constraining factor in sustainable algal-derived biofuel production. Additionally, scenarios with promising EROIfossil and GHG emissions profiles are plagued with high technological uncertainty.ConclusionsGiven the high variability in microalgae’s energy and environmental performance, careful evaluation of the algae-to-fuel supply chain is necessary to ensure the long-term sustainability of emerging algal biofuel systems. Alternative production scenarios and technologies may have the potential to reduce the critical demands of biomass production, and should be considered to make algae a viable and more efficient biofuel alternative.

An integration of algae-mediated wastewater treatment and resource recovery through anaerobic digestion

Fuzzy set scoring methodology for multi-objective sustainability assessment of algal biofuel pathways

Microalgae are well considered to be promising feedstocks for biodiesel production. Microalgae can be grown under different types of cultivation conditions and their biomass has tremendous potential to be used as biofuel feedstock and for other applications such as feed, food, cosmetics, pharmaceutical etc. Despite the many benefits and the significant development in the field of microalgal biodiesel production, there are several challenges including high cultivation cost and developing efficient downstream processing methods. The biomass production cost is high, which significantly hinders the use of microalgae as a feedstock. Most of the available literature is focused on upstream, single strain and single product strategy, where mainly algal lipids are used for biofuel production. Hence, for improving the sustainability of the algal biofuel production processes and related process economics, a multiple applications approach using integrated biorefinery and exploiting microalgae for environmental benefits is required. To explore the microalgal biorefinery concept it is vital to understand the various cultivation conditions and applications of biomass in different sectors. There are various strategies, which have potential to make algal biofuel technologies more economically feasible and environmentally sustainable. Use of alternative culture media, improving the biomass production and the efficiency of downstream processing (drying, cell disruption, lipid extraction etc.) algal biofuel technology economical. Utilizing lipid-extracted algae (LEA) for energy and aqua feed application will maximize overall economic return and will leave minimal residues as by-product. The major focus of this thesis was to utilize LEA as substrate for biomethane production and protein source in aquaculture feed. However, effect of preceding steps such as microalgae cultivation, biomass drying and cell disruption on major metabolites extraction was also studied. Microalgae were cultivated in different medium (domestic wastewater and BG11) and their biomass yields and biochemical composition (lipid, protein and carbohydrate) were compared. Different drying and cell disruption techniques were employed for lipid extraction and their effect on lipid, protein and carbohydrate yields were evaluated. The yield of major metabolites on whole cell and LEA were also compared. Suitable solvent systems were selected for optimum lipid extraction from wet and dry biomass with minimal toxic effect on LEA metabolites so that LEA can be further used for biomethane and aquaculture feed production. The choice of microalgae at large scale depends upon the number of factors such as their adaptability to large-scale cultivation, biomass production, major metabolites content, robustness towards the open system cultivation and contamination. In this study, S. obliquus and C. sorokiniana were cultivated in wastewater and BG11 medium at laboratory scale. Both strains are indigenous to KwaZulu-Natal. C. sorokiniana showed lower biomass and major metabolites (lipid, protein and carbohydrate) production at large scale compared to S. obliquus. Considering better adaptability to open cultivation, high biomass and metabolites yields, S. obliquus strain was selected for the LEA application study. Microalgae species, C. sorokiniana and S. obliquus were cultivated on BG11 and using different ratios of raw domestic wastewater and post-chlorinated wastewater as nutrient media. The cultivation of S. obliquus and C. sorokiniana showed biomass yield of 1.2-3.5 and 0.78-1.8 g L-1 in BG11 medium, respectively. While biomass yield observed in wastewater was 0.59-1.59 g L-1 for S. obliquus and 0.67-1.45 g L-1 for C. sorokiniana. The higher biomass yield in BG11 medium attributed to the higher nutrient contents in this medium compared to wastewater. The lipid contents for S. obliquus and C. sorokiniana were 20 and 16.5% dry cell weight (DCW), respectively when grown using BG11 medium. While increases in lipid contents of 26.25 and 29.4% DCW were found for S. obliquus and C. sorokiniana, respectively when cultivated using wastewater. Similarly, carbohydrate contents for S. obliquus and C. sorokiniana were 18 and 17% DCW, respectively for BG11 medium. Increased in carbohydrate contents of 25% for S. obliquus, 28.4% DCW for C. sorokiniana were observed for wastewater. Microalgae tend to accumulate more lipids and/or carbohydrates under nutrient stress condition. The nitrogen and phosphorus contents in wastewater are lower than BG11 medium, which were responsible for stressed condition for microalgae. With limited nutrients in wastewater compared to BG11 medium, growth of microalgae is also lower which resulted in lower protein content. Protein content for S. obliquus and C. sorokiniana in BG11 medium were 37.83-48.8 and 25-35.3% DCW, respectively. The protein contents for S. obliquus and C. sorokiniana in wastewater medium were 16.4-27.29 and 15.8-27.3% DCW, respectively. The biochemical composition depends upon the nutrient composition of the medium and cultivation conditions. The two selected microalgae have shown potential for nutrient removal while cultivated in wastewater. The removal efficiency by S. obliquus was found to be 76.13% for COD, 98.54% for nitrogen and 97.99% for phosphate. Microalgae C. sorokiniana cultivation in wastewater removed 69.38% COD, 86.93% nitrogen and 68.24% phosphates. Increased lipid accumulation in the cells was also recorded in stressed conditions due to low nutrient availability from wastewater. After harvesting of microalgae from culture media, the water content in thick algal slurry (>85% DCW) lowers the products recovery. To overcome this challenge drying and cell disruption are required to enhance the efficiency of lipid extraction. Where drying and cell disruption increase the viability of biomass for lipid extraction process. Three biomass-drying techniques viz. sun, oven and freeze-drying and four-cell disruption techniques viz. microwave, sonication, osmotic shock and autoclave disruption were studied for their effect on recovery of major metabolites from S. obliquus. Microalgae metabolites recovery from whole cell and LEA were analysed and compared. The results showed that after lipid extraction, LEA still contained comparable protein to whole algae biomass however, the carbohydrate concentration was reduced. Oven drying exhibited the highest recovery of all the major metabolites followed by freeze-drying; sun drying however, showed lower yields. Despite lower metabolites recovery sun-drying technique is preferable at large scale due to its easy application and cost-effective nature. The main drawback of sun drying technique is weather dependence and required longer period to dry. The microwave and autoclave microalgal cell disruption improved the lipid yield but loss of other compounds was observed. In osmotic shock treatment, due to poor cell disruption efficiency low lipid were obtained and comparably lower protein loss was noticed during lipid extraction. Lipid extraction is crucial step for microalgae biodiesel production. Solvent-assisted lipid extraction is widely used technique for lipid recovery from dry or wet algae biomass. In a biorefinery approach, it is vital to choose appropriate solvents for the optimum lipid extraction whilst having minimal effect on the remaining metabolites (protein and carbohydrates) in LEA. LEA could be used for energy generation or aquaculture feed applications. Six commonly used organic solvents/ solvent systems were used for lipid extraction from wet and dry biomass. The results showed that the lipid extraction efficiency depends strongly on types of biomass as well as solvent systems selected. Lipid extraction from wet algal biomass could reduce the processing steps and save energy incurred in drying. However, the water present in wet algal slurry acts as a barrier, which results in lower lipid yield compared to the dry biomass. The results revealed that among all six-selected solvents, chloroform: ethanol (1:1 v/v) was most effective if wet biomass used specifically for lipid purpose only. To explore the biorefinery concept, isopropanol/hexane composition is the most suitable solvent system because it is less toxic and resulted in high protein (20.07% DCW) and carbohydrate (22.87%) yields in LEA. For dry algal biomass, chloroform: methanol (2:1 v/v) is an appropriate solvent system if biomass used especially for lipid (19.25%) extraction. If LEA to be used for energy and/or aquaculture feed application, DCM: methanol was found to be a suitable solvent system, which gave 32.79% protein and 26.92% carbohydrate yield. Comparatively hexane has lower lipid recovery but shown higher protein and carbohydrate yield in LEA. Due to less toxic, easy to scale up and inexpensive, hexane is preferable as a solvent for lipid extraction if LEA is to be further utilized at large scale for energy or feed application. Anaerobic digestion (AD) of organic residues is well-researched technology for biomethane production. Whole microalgae and LEA has promising potential for biomethane production. The anaerobic sludge used as inoculum for microalgal biomass digestion. Biomethane production from whole algae and products extracted algae highly depends on sludge to algae biomass ratio for higher methane production. The extraction of metabolites also changes the biochemical composition of residual biomass, which can affect the biomethane production. It is vital to understand the effect of various product-extracted algae and as well as pre-treated algae on the biochemical methane potential. In order to compare biomethane potential, four types of biomass were selected namely sun dried powder algae (SDPA), mild heat-treated algae (MHTA), LEA (using hexane as lipid extracting solvent) and protein-extracted algae (PEA). The average methane (CH4) production rate was ~ 2.5 times higher for protein and lipid ex

Anaerobic digestion of organic fraction from hydrothermal liquefied algae wastewater byproduct

Microalgae have long been considered as one of most promising feedstocks with better characteristics for biofuels production over conventional energy crops. There have been a wide range of estimations on the feasibility of microalgal biofuels based on various productivity assumptions and data from different scales. The theoretical maximum algal biofuel productivity, however, can be calculated by the amount of solar irradiance and photosynthetic efficiency (PE), assuming other conditions are within the optimal range. Using the actual surface solar irradiance data around the world and PE of algal culture systems, maximum algal biomass and biofuel productivities were calculated, and feasibility of algal biofuel were assessed with the estimation. The results revealed that biofuel production would not easily meet the economic break‐even point and may not be sustainable at a large‐scale with the current algal biotechnology. Substantial reductions in the production cost, improvements in lipid productivity, recycling of resources, and utilization of non‐conventional resources will be necessary for feasible mass production of algal biofuel. Among the emerging technologies, cultivation of microalgae in the ocean shows great potentials to meet the resource requirements and economic feasibility in algal biofuel production by utilizing various marine resources.

The Department of Energy (DOE) Bioenergy Technologies Office (BETO) Multi-year Program Plan (MYPP) describes the bioenergy objectives pursued by BETO, the strategies for achieving those objectives, the current state of technology (SOT), and a number of design cases that explore cost and operational performance required to advance the SOT towards middle and long term goals (MYPP, 2016). Two options for converting algae to biofuel intermediates were considered in the MYPP, namely algal biofuel production via lipid extraction and algal biofuel production by thermal processing. The first option, lipid extraction, is represented by the Combined Algae Processing (CAP) pathway in which algae are hydrolyzed in a weak acid pretreatment step. The treated slurry is fermented for ethanol production from sugars. The fermentation stillage contains most of the lipids from the original biomass, which are recovered through wet solvent extraction. The process residuals after lipid extraction, which contain much of the original mass of amino acids and proteins, are directed to anaerobic digestion (AD) for biogas production and recycle of N and P nutrients. The second option, thermal processing, comprises direct hydrothermal liquefaction (HTL) of the wet biomass, separation of aqueous, gas, and oil phases, and treatment of the aqueous phase with catalytic hydrothermal gasification (CHG) to produce biogas and to recover N and P nutrients. The present report describes a life cycle analysis of energy use and greenhouse gas (GHG) emissions of the CAP and HTL options for the three scenarios just described. Water use is also reported. Water use during algal biofuel production comes from evaporation during cultivation, discharge to bleed streams to control pond salinity (“blowdown”), and from use during preprocessing and upgrading. For scenarios considered to date, most water use was from evaporation and, secondarily, from bleed streams. Other use was relatively small at the level of fidelity being modeled now.

Recent research has proposed integrating wastewater treatment with algae cultivation as a way of producing algal biofuels at a commercial scale more sustainably. This study evaluates the environmental performance of wastewater-based algal biofuels with a well-to-wheel life cycle assessment (LCA). Production pathways examined include different nutrient sources (municipal wastewater influent to the activated sludge process, centrate from the sludge drying process, swine manure, and freshwater with synthetic fertilizers) combined with emerging biomass conversion technologies (microwave pyrolysis, combustion, wet lipid extraction, and hydrothermal liquefaction). Results show that the environmental performance of wastewater-based algal biofuels is generally better than freshwater-based algal biofuels, but depends on the characteristics of the wastewater and the conversion technologies. Of 16 pathways compared, only the centrate cultivation with wet lipid extraction pathway and the centrate cultivation with combustion pathway have lower impacts than petroleum diesel in all environmental categories examined (fossil fuel use, greenhouse gas emissions, eutrophication potential, and consumptive water use). The potential for large-scale implementation of centrate-based algal biofuel, however, is limited by availability of centrate. Thus, it is unlikely that algal biofuels can provide a large-scale and environmentally preferable alternative to petroleum transportation fuels without considerable improvement in current production technologies. Additionally, the cobenefit of wastewater-based algal biofuel production as an alternate means of treating various wastewaters should be further explored.

Biofuels, derived from organic materials, have emerged as a sustainable alternative to traditional fossil fuels, addressing environmental concerns and energy security. This chapter provides an overview of biofuel production methods, the diverse range of plants used as feedstock, the pivotal role of microbes in biofuel generation, applications and future trends in the field. Production Methods: Biofuels are primarily produced through biochemical and thermochemical processes. Biochemical methods involve the conversion of biomass into fuel through biological agents, while thermochemical methods utilize heat and catalysts for conversion. Common biochemical methods include fermentation and anaerobic digestion etc. Plants Used for Biofuel Production: Various plant sources are employed for biofuel production, each with distinct advantages. Dedicated energy crops such as sugarcane, jatropha, corns etc are cultivated for their high biomass yield. Additionally, agricultural residues like corn stover and forestry by-products are utilized, contributing to the sustainability of biofuel feedstock. Microbes in Biofuel Production: Microorganisms play a crucial role in biofuel production by aiding in the fermentation process. Yeasts, bacteria, and fungi are employed to convert sugars and other organic compounds present in biomass into biofuels. Notable examples include Saccharomyces cerevisiae for ethanol production and Clostridium species for butanol production. Future Trends in Biofuels: The biofuel industry is witnessing constant innovation and evolution. Advances in genetic engineering aim to enhance the efficiency of biofuel crops and microbial strains, leading to improved yields and reduced production costs. Second and third-generation biofuels, derived from non-food crops and waste materials, are gaining prominence, addressing concerns related to food security and land use. Biofuels have diverse applications across various sectors, contributing to a more sustainable and environmentally friendly energy landscape. In the transportation sector, biofuels, particularly bioethanol and biodiesel, are widely used as alternatives to conventional fossil fuels, reducing greenhouse gas emissions and mitigating climate change. Aviation biofuels are being explored as a cleaner alternative for air travel. In the industrial sector, biofuels can be utilized for heat and power generation, providing a renewable energy source that decreases reliance on finite fossil fuel resources. Additionally, biofuels play a crucial role in agriculture, serving as a source of renewable energy for farm machinery. As an alternative to traditional fuels, biofuels contribute to energy security, promote rural development through the cultivation of biofuel crops, and offer a sustainable pathway towards a more eco-friendly energy future. Additionally, some research area are discussed on developing novel technologies, such as algae-based biofuels and synthetic biology approaches, further expanding the scope of sustainable fuel production. As the world transitions towards a greener energy future, the integration of biofuels into existing energy systems is poised to play a pivotal role in mitigating climate change and ensuring a more sustainable global energy landscape.

A national-scale comparison of resource and nutrient demands for algae-based biofuel production by lipid extraction and hydrothermal liquefaction

The combination of anaerobic digestion and hydrothermal liquefaction can provide enhanced energy production from animal wastes such as cow manure. Hydrothermal liquefaction (HTL) of anaerobic digestate is a novel approach for waste management to recover residual carbon Anaerobic digestion of cow manure was conducted at room temperature with different hydraulic retention times (HRT) viz. 10, 18, 28, 38, 50 and 60 days. The digested cow manure (16%w/w dry weight solids) obtained from various HRTs was subjected to hydrothermal liquefaction at 350°C, 18MPa for a fixed reaction time of 30 min in the presence of 5 wt % Na2CO3. The results showed cumulative biogas production in the range of 3.9–22.6 m3/kgVSadded. HTL of the resultant digestates led to ∼20–42 wt % biocrude yield. The biocrude has a higher heating value (HHV) of 28.4–31.2 MJ/kg. About 76% energy, ∼51–83% carbon and ∼2–4% nitrogen was recovered in the biocrude following HTL of the digestates. A positive energy balance was achieved for the products derived from the combination of anaerobic digestion and hydrothermal liquefaction. © 2015 American Institute of Chemical Engineers Environ Prog, 34: 1662–1673, 2015

The Upper Mississippi River Basin and Ohio‐Tennessee River Basin comprise the majority of the United States Corn Belt region, resulting in degraded Mississippi River and Gulf of Mexico water quality. To address the water quality implications of increased biofuel production, biofuel scenarios were tested with a Soil and Water Assessment Tool (SWAT) model revision featuring improved biofuel crop representation. Scenarios included corn stover removal and the inclusion of two perennial bioenergy crops, switchgrass and Miscanthus, grown on marginal lands (slopes >2% and erosion rates >2 t/ha) and nonmarginal lands. The SWAT model estimates show water quality is not very sensitive to stover removal. The perennial bioenergy crops reduce simulated sediment, nitrogen (N), and phosphorus (P) yields by up to 60%. Simulated sediment and P reductions in marginal lands were generally twice that occurring in the nonmarginal lands. The highest unit area reductions of N occurred in the less sloping tile‐drained lands. Productivity showed corn grain yield was independent from stover removal, while yields of the two perennial bioenergy crops were similar in the marginal and nonmarginal lands. The results suggest planning for biofuel production in the Corn Belt could include the removal of stover in productive corn areas, and the planting of perennial bioenergy crops in marginal land and in low‐sloped tile‐drained areas characterized by high N pollution. Editor's note: This paper is part of the featured series on SWAT Applications for Emerging Hydrologic and Water Quality Challenges. See the February 2017 issue for the introduction and background to the series.

This manuscript explores the imperative role of biomass in shaping the global bioeconomy, necessitated by escalating energy demands and the consequent environmental challenges posed by fossil fuel dependency. This paper delineates the diverse forms of biomass — from lignocellulosic materials to organic waste and algae — each holding distinct chemical compositions and applications within the bioeconomy. Investigating biomass conversion technologies (i.e. thermochemical, biochemical and chemical) provides a comprehensive understanding of their merits and limitations in energy production and resource optimisation. Specifically, it delves into pyrolysis, gasification, hydrothermal liquefaction, torrefaction, anaerobic digestion and transesterification, elucidating their mechanisms and contributions to energy generation and biofuel production. Moreover, the study incorporates bibliometric analysis, depicting thematic clusters in biomass research and highlighting the evolving trends in its application within the bioeconomy. The primary focus of studies within the initial cluster revolves around utilising biomass for a global bioeconomy through thermochemical conversion methods. Overall, this review underscores the indispensable role of biomass as a renewable and adaptable resource, pivotal in steering the transition towards a sustainable bio-based economy amid global environmental and socio-economic challenges.

Techno-economic and life cycle analysis of biofuel production via hydrothermal liquefaction of microalgae in a methanol-water system and catalytic hydrotreatment using hydrochar as a catalyst support