Swirling flow implementation in a photobioreactor for batch and continuous cultures of Porphyridium cruentum

Light is the main limiting factor in photoautotrophic-intensive production of microorganisms, and improvement of its use is an important concern for photobioreactor design and operation. Swirling flows, which are known to improve mass and photon transfers, were applied to annular light chambers of a photobioreactor and studied by simulation and microalgal culture. Two hydrodynamic conditions were compared: axial flow generating poor radial mixing, and tangential flow generating three-dimensional swirling motion. Batch and continuous cultures of the Rhodophyte Porphyridium cruentum were performed in a 100-L, 1.5-m(2), fully controlled photobioreactor with eight light chambers. The inlet design of these chambers was modified to create the hydrodynamic conditions for comparison. Various intensities of swirling motion were used, characterized by the velocity factor (VF), defined as the ratio between annular chamber flow and inlet aperture sections. Experiments were performed within the range of photon flux densities (PFD) optimizing the yield of light energy transformation into living substance for the species and the temperature used. Culture kinetics with swirling flows generated by apertures of VF = 2, 4, and 9 were compared with pseudoaxial VF = 2 chosen as reference. Batch cultures with VF = 4 swirling flow showed no significant difference, whereas continuous cultures proved more discriminating. Although no significant difference was obtained for VF = 2, a 7% increase of steady-state productivity and a 26% decrease in time required to reach this steady state were obtained with VF = 4 swirling flow. This beneficial effect of swirling flow could have accounted for increased mixing. Conversely, VF = 9 swirling flow resulted in a 9% decrease of steady-state productivity and a 9% increase in the time required to reach this steady state, a negative effect that could have accounted for increased shear stress. CO(2) bioconversion yield at steady state showed a 34% increase for VF = 4. These results suggest that swirling motion makes microalgal cultures more efficient, provided that the resulting adverse effects remain acceptable. Experimental investigation was completed by a theoretical approach in which simulation of continuous cultures of P. cruentum was based on the hydrodynamic conditions achieved in the photobioreactor. Although the results obtained with pseudoaxial flow were correctly predicted, simulations with swirling flow showed a marked enhancement of productivity not observed experimentally. The influence of side effects induced by increased mixing (particularly hydrodynamic shear stress) was considered with respect to modeling assumptions. Comparison of experimental results with theoretical simulation provided a better understanding of the mixing effect, a key factor in improving the efficiency of such bioprocesses.