Interchangeable modular design and operation of photo-bioreactors for Chlorella vulgaris cultivation towards a zero-waste biorefinery

This study explores diverse cultivation modes for Chlorella vulgaris within a biorefinery at pilot scale that produces both biodiesel by transesterification of waste frying oils and syngas by gasification of organic wood waste. Given microalgae's comparatively modest biofuel yield relative to principal biorefinery products, the microalgae cultivation process is designed on the biofuels production rates. Liquid and gaseous waste streams are recycled inside the biorefinery: crude glycerol is mixed with wood to enhance the quality of syngas, wastewater is fed to microalgae so as flue gas. Also, the oil extracted from microalgae contributes to produce biodiesel and the waste cells are gasified. Considering that the optimal fit for each cultivation mode varies with the shape of the reactor, we propose a modular approach to assemble them in batteries of tubular, bubble flow, and airlift reactors, and present an operating design criterion that can fulfill the mass balance of the plant by adding/transforming the number of units inside the different batteries. Methods to adjust the operating conditions and control the operating parameters are also discussed. The designed configurations were operated recycling nominal waste streams of about 30 L d^-1 of wastewater and 90 Nm³ h^-1 of flue gas. Results confirm that the most advantageous one, in terms of volume per recycled waste streams, is a battery of 16 airlift reactors, operating in mixotrophic mode, with growing rate of 0.427 d^-1, yield of 3.06, glycerol conversion 39 %, CO₂ removal 64 % of inlet 6-10 %(mol) concentration. The same nominal waste streams can also be managed by 40 tubular reactors in almost heterotrophic conditions coupled with 12 bubble columns in autotrophic conditions; working respectively at growing rates of 0.395 d^-1 and 0.362 d^-1 and yields of 2.94 and 2.84. The battery of tubular reactors reached a glycerol conversion of 45 % and the array of bubble columns removed about 51 % of inlet 12-20 %(mol) CO₂ concentration. A complete comparison is reported also in terms of dimensionless numbers and pumping/mixing requirements.