Algae cultivation scale-up with Lgem PBRs

Added on 30 May 2025

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Scaling algae cultivation from laboratory conditions to industrial production scale is a complex process that requires careful consideration of biological, technical, and operational factors. This guide provides practical insights into scaling with Lgem’s photobioreactors (PBRs), addressing common challenges and strategies to ensure efficient and stable production at larger scales.

1. Key steps in transitioning from lab-scale to pilot-scale to industrial-scale cultivation

Environmental control variations

Lab environments offer high control over culture conditions such as temperature, pH, and light and nutrient availability. Scaling up introduces environmental variability, especially in outdoor systems subject to seasonal and daily variations. To mitigate this, indoor systems can replicate controlled lab conditions more effectively. Fully indoor cultivation can also be economically feasible, provided electricity prices remain below €0.15 per kWh

Impact of system size on circulation and light distribution

As system size increases, circulation times extend significantly—ranging from 6 to 12 minutes in Lab-25 systems, 12 to 30 minutes in pilot setups, and up to 20 to 40 minutes in full-scale industrial systems. The increased circulation times affect nutrient uptake and gas exchange throughout the helix. In addition, at Lgem, tube diameters increase from 32 mm (OD) at lab scale to 65 mm (OD) at pilot and industrial scale, altering light penetration and requiring recalibration of the applied light intensity to maintain the same productivity.