Tackling old challenges in microalgal biotechnology: the role of photobioreactors to advance the technology readiness level
Open accessAbstract
Microalgae biotechnology has taken the world by storm. However, despite its great potential promise, it still cannot be considered a fully consolidated technology due to a crucial challenge: the low rates of biomass productivity. To overcome this hurdle, photobioreactors have been developed as an innovative solution, promising to increase the efficiency of microalgae cultures by providing optimized conditions. However, the results obtained with these systems do not always meet initial expectations, and their large-scale implementation faces complex technical challenges. In light of this, the present review addresses the main aspects related to the design and engineering of photobioreactors, highlighting their potentialities and limitations in overcoming the critical challenges of microalgal biotechnology. Furthermore, we discuss the current technological readiness level and the commercial readiness index of microalgae-based bioproducts from the perspective of industrial-scale production.
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Differences between laboratory and industrial-scale microalgae processes are largely attributed to the sensitivity of microalgae performance to critical operational parameters.
“In fact, the differences observed between laboratory and industrial-scale processes are largely attributed to the sensitivity of microalgae performance to critical operational parameters.”
From Microalgae biotechnology and its role in sustainable and healthy food design (2025) · cites this paper as Deprá et al., 2024
Section 2 says process control decreases as cultivation moves to larger volumes, and Section 4 says control of temperature, pH, light, and nutrients maintains productivity. Together these support the importance of operational parameters, but the paper attributes the scale-up loss of control primarily to insufficient understanding of expansion requirements; it does not specifically say that laboratory–industrial differences are largely caused by microalgae’s sensitivity to those parameters. The indexed passages provide no page numbers. (LLM, conf=0.78)
Experimental — accuracy not yet measuredPolycarbonate combines good light transmittance, high mechanical strength, lower susceptibility to biofouling, and a favorable cost-benefit ratio for photobioreactor construction.
“Polycarbonate, on the other hand, represents a promising alternative, as it combines good light transmittance, high mechanical strength, and lower susceptibility to biofouling, while also offering a more favorable cost–benefit ratio for photobioreactor construction (Deprá et al., 2024).”
From Microalgae biotechnology and its role in sustainable and healthy food design (2025) · cites this paper as Deprá et al., 2024
Section 2 reports that polycarbonate has 85–90% light transmittance, greater impact resistance, and higher resistance to biofouling than the other materials discussed. The paper discusses photobioreactor installation costs in Section 3, but does not establish that polycarbonate itself offers a more favorable cost–benefit ratio. (LLM, conf=0.88)
Experimental — accuracy not yet measuredThe majority of these investigations have been conducted at the laboratory scale.
“However, it is important to recognize that the majority of these investigations have been conducted at the laboratory scale.”
From Microalgae biotechnology and its role in sustainable and healthy food design (2025) · cites this paper as Deprá et al., 2024
Section 2, “Biomass Production—The Death Valley of Microalgal Biotechnology” (page not provided), says laboratory-scale work involves tests for process optimization before parameters are transferred to larger scales. It does not say that a majority of investigations have been conducted at laboratory scale. (LLM, conf=0.78)
Experimental — accuracy not yet measuredDetailed techno-economic assessments are required before full-scale implementation, as changes in cell characteristics such as morphology or cell wall composition can impact downstream processing costs, regulatory compliance, and genetic stability.
“Detailed techno-economic assessments are required before full-scale implementation, as changes in cell characteristics—such as morphology or cell wall composition—can impact downstream processing costs, regulatory compliance, and genetic stability.”
From Microalgae biotechnology and its role in sustainable and healthy food design (2025) · cites this paper as Deprá et al., 2024
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Experimental — accuracy not yet measuredVariations in operational parameters lead to substantial differences in growth rates, biomass yield, and metabolite accumulation, widening the performance gap between laboratory and industrial operations.
“Consequently, variations in these parameters lead to substantial differences in growth rates, biomass yield, and metabolite accumulation, thereby widening the performance gap between laboratory and industrial operations”
From Microalgae biotechnology and its role in sustainable and healthy food design (2025) · cites this paper as Deprá et al., 2024
Risks of contamination, biofilm formation in photobioreactors, inadequate light distribution, shear stress, and limited temperature control compromise productivity and industrial viability of microalgae production.
“Technologically, the risks of contamination, biofilm formation in photobioreactors, inadequate light distribution, shear stress, and limited temperature control compromise not only productivity but also industrial viability (Deprá et al., 2024).”
From Microalgae biotechnology and its role in sustainable and healthy food design (2025) · cites this paper as Deprá et al., 2024
Translating these findings into industrial practice requires careful validation, as process performance and economic feasibility can differ significantly when scaled up.
“Translating these findings into industrial practice requires careful validation, as process performance and economic feasibility can differ significantly when scaled up.”
From Microalgae biotechnology and its role in sustainable and healthy food design (2025) · cites this paper as Deprá et al., 2024
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Self-citation
- Authors
- Deprá, M. C., Dias, R. R., Zepka, L. Q., & Jacob-Lopes, E.
- Affiliations
- Universidade Federal de Santa Maria (BR)
- Bioprocess Intensification Group, Federal University of Santa Maria, UFSM, Roraima Avenue 1000, Santa Maria 97105-900, RS, Brazil
- Corresponding author
- Deprá, Mariany Costa
- Venue
- Processes
- Publisher
- MDPI AG
- Published
- 2024-12-29
- Volume
- 13
- Issue
- 1
- Pages
- 51
- ISSN
- 2227-9717 (ISSN-L)
- OpenAlex
- W4405928337
- Cited by
- 31
- References
- 113
- Citations by year
- 2026: 19 · 2025: 12
- FWCI
- 2.07
- Type
- journal article
- Language
- en
- Open access
- gold
- doi.org
- Licence
- Locations
- Processes (publishedVersion, cc-by)
- Topics
- Physical Sciences › Energy › Renewable Energy, Sustainability and the Environment › Algal biology and biofuel production
- Physical Sciences › Engineering › Biomedical Engineering › Fluid Dynamics and Mixing
- Life Sciences › Biochemistry, Genetics and Molecular Biology › Molecular Biology › Microbial Metabolic Engineering and Bioproduction
- Keywords
- photobioreactors, microalgal biotechnology, microalgae productivity, technology readiness level
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