Optimizing biofuel production from algae using four-element framework: Insights for maximum economic returns

Abstract

This paper introduces a Four Element Strategy (FES) focused on concentration of CO2 gas (Cc,g), energy input to the process, concentration of nutrients, and the type of algal strain to maximize biofuel production (BYP) from algae strains and evaluate associated economic benefits. Two algal strains encompassing slain algae Nannochloropsis sp. (Ns), and freshwater strain Chlorella vulgaris (Cv) were used in the current study. Response Surface Methodology (RSM) and Box Behnkin Design (BBD) are integrated with a biokinetic model to explore the relationships among growth parameters in the ranges; Cc,g ∼ 0.03–20 %), Nitrogen (N) to phosphorus (P) ratio (RN/P)∼1–11, and light intensity (LI)∼ 100–400 µE m⁻² s⁻¹ with corresponding CO2 bio-fixation rate (RCO2, g L⁻¹ d⁻¹), biomass accumulation (X, g L⁻¹), and algal growth rate (µ, d⁻¹). Optimization results indicate that the most productive conditions involve LI in the range of 100–270 µE m⁻² s⁻¹, Cc,g between 0.03 % and 15 %, and RN/P of 3.5–11, achieving maximum RCO2, X, and µ at 1 g L⁻¹ d⁻¹, 6 g L⁻¹, and 1.6 d⁻¹, respectively. Further optimization using the desirability function supports achieving RCO2 of 1.2 g L⁻¹ d⁻¹, X of 1.8 g L⁻¹, and µ of 1.7 d⁻¹, with RN/P, Cc,g, and LI at 11, 4.5 %, and 200 µE m⁻² s⁻¹, respectively. Notably, Ns demonstrated higher nutrient uptake rates and BYP compared to Cv, with total production costs of $0.629/L and respective required cost coverages of $0.138 and $0.375 for Ns and Cv. This study offers a comprehensive guideline for large-scale microalgae cultivation technology (MCT) processes, providing insights into optimizing conditions for biofuel production while considering economic viability.