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Microalgae production is receiving an increasing interest both by research institutions and commercial companies (Di Caprio et al., 2016). This is due to the growing consciousness of the need to move towards renewable, sustainable feedstoks for commodities production (Wang et al., 2012). However, process development at industrial scale, either based on open or closed photobioreactors, still is in a rather early stage and there is room for further development (Morweiser et al., 2010), especially aimed at reducing process costs. In this work an innovative low-cost technology for microalgae production, currently under development at Palermo University, is described. The main ways through which the goal of costs containment is pursued are (i) the adoption of thin walled transparent tubing for the photo bioreactor, and (ii) an evacuated-head air-lift system. To the aim of providing a proof-of-concept of these ideas, a 500-liter pilot plant was built. This is presently being operated in semi-continuous mode under solar irradiation and external climatic conditions.

The present work is devoted to providing an insight into the solid-particle distribution within top-covered unbaffled stirred tanks via purposely collected local experimental data. Experiments were carried out on a lab- scale unbaffled stirred tank by making use of a recently introduced technique named Laser Sheet Image Analysis (LSIA). In its original formulation, the technique includes an image post-processing procedure to delete reflection effects on results. In the framework of the present work, a method combining the use of purposely produced fluorescent particles and a suitable camera high pass filter was devised and presented. Results collected with (new method) and without (old fashion) fluorescent particles were compared for comparison purposes and a satisfactory agreement was found, thus validating both the procedures devised to delete reflections. LSIA technique in the novel version was used to investigate the distribution of solid particles at different agitation speeds in an unbaffled tank stirred by either a marine propeller or by a Rushton turbine. On overall, collected results show that the propeller configuration provides somewhat better particle distribution throughout the tank as compared with Rushton turbine operated at the same agitation speed. The two stable toroidal attractors for solid particles there observed are recognizable also here, though with a configuration significantly different due to the diverse flow fields.

Power savings is a problem of crucial importance nowadays. In process industry, suspension of solid particles into liquids is usually obtained by employing stirred tanks, which often are very power demanding. Notwithstanding tanks provided with baffles are traditionally adopted for this task, recent studies have shown that power reductions can be obtained in top-covered unbaffled vessels. In the present work experiments were carried out in a top-covered unbaffled vessel with a diameter T=0.19m and filled with distilled water and silica particles. Two different turbines were tested: a standard six-bladed Rushton Turbine (RT) and a 45° four bladed Pitched Blade Turbine (PBT). For the case of the PBT both the up-pumping (PBT-Up) and the down- pumping (PBT-Down) operation mode were tested. Two different impeller sizes D (T/3 and T/2) and clearances C (T/3 and T/10) were investigated. The effects of particle size and concentration were also assessed. Investigations concern the assessment of the minimum impeller speed for complete suspension (Njs) along with the measurement of the relevant power consumption (Pjs) aiming at identifying the most efficient tank-turbine configuration among those investigated here. Results were also compared with corresponding ones pertaining to baffled tanks (obtained via correlations available in the literature). Results have shown that the RT with D=T/3 and C=T/3 and the PBT-Up with D=T/2 and C=T/10 appear to be the most convenient (least power demanding) options. Finally, a significant power saving with respect to the most efficient baffled configurations was observed thus confirming the convenience of operating solid-liquid suspensions in an unbaffled system for all those processes where the mixing time is not a limiting factor.

Cultivation of microorganisms, plants or animal cells requires liquid agitation in order to ensure oxygen and nutrient transfer and to maintain cell suspension. Many studies on animal cell damage due to mechanical agitation and sparging aeration have shown that mechanical damage of freely suspended animal cells is in most cases associated with bursting bubbles at the air–liquid interface (Barrett et al., 2010). Gas bubbles are usually generated by direct air sparging aimed at supplying oxygen to the culture medium. Mechanical agitation may also introduce gas bubbles in the culture medium via vortexing entrainment from the free surface. In this work oxygen transfer performance of an unbaffled stirred bioreactor, with various aspect ratios, is presented in view of its use as a biochemical reactor for animal cell growth. In practice oxygen mass transfer occurs through the (more or less deep) free surface vortex which takes place when agitation is started in unbaffled vessels. If this vortex is not allowed to reach impeller blades, bubble formation and subsequent bursting at the free-surface is avoided. Experimental results show that this kind of bioreactor can provide sufficient oxygen mass transfer for animal cell growth, so resulting in a viable alternative to the more common sparged reactors. The mass- transfer performance observed with the different aspect ratio configurations is also presented and discussed.

There is a growing interest in using unbaffled stirred tanks for addressing certain processing needs. In this work, digital image analysis coupled with a suitable shadowgraphy-based technique is used to investigate the shape of the free-surface vortex that forms in uncovered unbaffled stirred tanks. The technique is based on back-lighting the vessel and suitably averaging vortex shape over time. Impeller clearance from vessel bottom and tank filling level are varied to investigate their influence on vortex shape. A correlation is finally proposed to fully describe vortex shape also when the vortex encompasses the impeller.

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The aim of this work is setting up the conditions of an “iso-actinic” photobioreactor that is a photoreactor for the cultivation of microalgae in which the local volumetric rate of photon absorption (LVRPA), can be considered uniform to a good extent. We describe the composition of this cheap photoreactor and how we made it. The system is driven by an Arduino platform that makes it possible to control light intensity as well as light-dark cycles. Preliminary results obtained by growing Nannochloropsis gaditana, a microalga famous for its fat content, in this innovative reactor are presented. We finally observed how microalgae responds to flashing light irradiation.