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Photobioreactor design and operation are discussed in terms of mixing, carbon utilization, and the accumulation of photosynthetically produced oxygen. The open raceway pond is the primary type of reactor considered; however small diameter (1-5 cm) horizontal glass tubular reactors are compared to ponds in several respects. These are representative of the diversity in photobioreactor design: low capital cost, open systems and high capital cost, closed systems. Two 100-m(2) raceways were operated to provide input data and to validate analytical results. With a planktonic Chlorella sp., no significant difference in productivity was noted between one pond mixed at 30 cm/s and another mixed from 1 to 30 cm/s. Thus, power consumption or CO(2) outgassing limits maximal mixing velocities. Mixing power inputs measured in 100-m(2) ponds agreed fairly well with those calculated by the use of Manning's equation. A typically configured tubular reactor flowing full (1 cm diameter, 30 cm/s) consumes 10 times as much energy as a typical pond (20 cm deep flowing at 20 cm/s). Tubular reactors that flow only partially full would be limited by large hydraulic head losses to very short sections (as little as 2 m length at 30 cm/s flow) or very low flow velocities. Open ponds have greater CO(2) storage capacity than tubular reactors because of their greater culture volume per square meter (100-300 L/m(2) vs. 8-40 L/m(2) for 1-5-cm tubes). However, after recarbonation, open ponds tend to desorb CO(2) to the atmosphere. Thus ponds must be operated at higher pH and lower alkalinity than would be possible with tubular reactors if cost of carbon is a constraint. The mass transfer coefficient, K(L), for CO(2) release through the surface of a 100-m(2) pond was determined to be 0.10 m/h. Oxygen buildup would be a serious problem with any enclosed reactor, especially small-diameter tubes. At maximal rates of photosynthesis, a 1-cm tubular reactor would accumulate 8-10 mg O(2)/L/min. This may result in concentrations of oxygen reaching 100 mg/L, even with very frequent gas exchange. In an open pond, dissolved oxygen rises much more slowly as a consequence of the much greater volume per unit surface area and the outgassing of oxygen to the atmosphere. The maximum concentration of dissolved oxygen is typically 25-40 mg/L. The major advantage of enclosed reactors lies in the potential for aseptic operation, a product value which justifies the expense. For most products of algal mass cultivation, open ponds are the only feasible photobioreactor design capable of meeting the economic and operating requirements of such systems, provided desirable species can be maintained.

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Abstract:The potential of microalgae biomass production for low-cost commodities-biofuels and animal feeds-using sunlight and CO 2 is reviewed. Microalgae are currently cultivated in relatively small-scale systems, mainly for high value human nutritional products. For commodities, production costs must be decreased by an order of magnitude, and high productivity algal strains must be developed that can be stably cultivated in large open ponds and harvested by low-cost processes. For animal feeds, the algal biomass must be high in digestible protein and long-chain omega-3 fatty acids that can substitute for fish meal and fish oils. Biofuels will require a high content of vegetable oils (preferably triglycerides), hydrocarbons or fermentable carbohydrates. Many different cultivation systems, algal species, harvesting methods, and biomass processing technologies are being developed worldwide. However, only raceway-type open pond systems are suitable for the production of low-cost commodities.

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Microalgal biomass production offers a number of advantages over conventional biomass production including, higher productivities, use of otherwise non productive land, reuse and recovery of waste nutrients, use of saline or brackish waters, and reuse of CO 2 from power-plant flue-gas or similar sources. Microalgal biomass production and utilization offers potential for greenhouse gas (GHG) avoidance by providing biofuel replacement of fossil fuels and carbon-neutral animal feeds. This paper presents an initial analysis of the potential for GHG avoidance using a proposed algal biomass production system coupled to recovery of flue-gas CO 2 combined with waste sludge and/or animal manure utilization. A model is constructed around a 50 megawatt (MW) natural gas fired electrical generation plant operating at 50% capacity as a semi base-load facility. This facility is projected to produce 216 million kWh/240-day season while releasing 30.3 million kg-C/season of GHG-CO 2. An algal system designed to capture 70% of flue-gas CO 2 would produce 42,400 metric tons (dry wt.) of algal biomass/season, and require 880 ha of high-rate algal ponds operating at a productivity of 20 g-dry-wt/m 2-day. This algal biomass is assumed to be fractionated into 20% extractable algal oil, useful for biodiesel, with the 50% protein content providing animal feed replacement, and 30% residual algal biomass digested to produce methane gas, providing gross GHG avoidances of 20%, 8.5% and 7.8% respectively. The total gross GHG avoidance potential of 36.3% results in a net GHG avoidance of 26.3% after accounting for 10% parasitic energy costs. Parasitic energy is required to deliver CO 2 to