This article presents an engineering study of an integrated system to produce bio-oil from microalgae biomass. The analysis is based on a pilot plant located at Minami-soma Fukushima, Japan, which further simulates 1 ha based-cultivation. Municipal wastewater and flue gases were utilized as nutrient sources for the microalgae culture of the proposed design. A flow sheet diagram of the integrated plant was synthesized by process engineering software to allow simulation of a continuous system. The design and sizing of the process equipment were performed to obtain a realistic estimation of possible production cost. The results demonstrated that nutrient savings was achieved by wastewater and CO₂ utilization to the polyculture of native microalgae. Process simulation gave an estimated CO₂ sequestration of 82.77 to 140.58 tons ha⁻¹year⁻¹ with 63 to 107 tons ha⁻¹year⁻¹ of potential biomass production. The integrated process significantly improved the energy balance and economics of biofuel production and also the wastewater treatment plant (WWTP). The economic analysis confirmed that higher biomass production and technology improvement were required to achieve operational feasibility and profitability of the current microalgae-based bio-oil production.

This study investigates the potential of microalgae oil production as an alternative renewable energy source, in a pilot project located at Minamisoma City in the Fukushima Prefecture of Japan. The algal communities used in this research were the locally mixed species, which were mainly composed of Desmodesmus collected from the Minamisoma pilot project. The microalgae oil-production processes in Minamisoma consisted of three stages: cultivation, dewatering, and extraction. The estimated theoretical input-energy requirement for extracting oil was 137.25 MJ to process 50 m³ of microalgae, which was divided into cultivation 15.40 MJ, centrifuge 13.39 MJ, drum filter 14.17 MJ, and hydrothermal liquefaction (HTL) 94.29 MJ. The energy profit ratio (EPR) was 1.41. The total energy requirement was highest in the HTL process (68%) followed by cultivation (11%) and the drum filter (10%). The EPR value increased along with the yield in the cultivation process. Using HTL, the microalgae biomass could be converted to bio-crude oil to increase the oil yield in the extraction process. Therefore, in the long run, the HTL process could help lower production costs, due to the lack of chemical additions, for extracting oil in the downstream estimation of the energy requirements for microalgae oil production.

Microalgae have attracted significant attention worldwide as one of the most promising feedstock fossil fuel alternatives. However, there are a few challenges for algal fuels to compete with fossil fuels that need to be addressed. Therefore, this study reviews the R&D status of microalgae-based polyculture and biocrude oil production, along with wastewater treatment. Mixotrophic algae are free to some extent from light restrictions using organic matter and have the ability to grow well even in deep water-depth cultivation. It is proposed that integrating the mixotrophic microalgae polyculture and wastewater treatment process is the most promising and harmonizing means to simultaneously increase capacities of microalgae biomass production and wastewater treatment with a low land footprint and high robustness to perturbations. A large amount of mixotrophic algae biomass is harvested, concentrated, and dewatered by combining highly efficient sedimentation through flocculation and energy efficient filtration, which reduce the carbon footprint for algae fuel production and coincide with the subsequent hydrothermal liquefaction (HTL) conversion. HTL products are obtained with a relatively low carbon footprint and separated into biocrude oil, solid, aqueous, and gas fractions. Algae biomass feedstock-based HTL conversion has a high biocrude oil yield and quality available for existing oil refineries; it also has a bioavailability of the recycled nitrogen and phosphorus from the aqueous phase of algae community HTL. The HTL biocrude oil represents higher sustainability than conventional liquid fuels and other biofuels for the combination of greenhouse gas (GHG) and energy return on investment (EROI). Deep water-depth polyculture of mixotrophic microalgae using sewage has a high potential to produce sustainable biocrude oil within the land area of existing sewage treatment plants in Japan to fulfill imported crude oil.