Microalgae are a promising biomass source because of their capability to fixate CO₂ very efficiently. In this study, the potential of Microchloropsis salina biomass as a feedstock for fermentation was explored, focusing on biomass hydrolysis by employing various mechanical and chemical cell disruption strategies in combination with enzymatic hydrolysis. Among the mechanical cell disruption methods investigated on a lab scale, namely ultrasonication, bead milling, and high-pressure homogenization, the most effective was bead milling using stainless-steel beads with a diameter of 2 mm. In this way, 87–97% of the cells were disrupted in 40 min using a mixer mill. High-pressure homogenization was also effective, achieving 86% disruption efficiency after four passes on a 30–200 L scale using biomass with 15% (w/w) solids content. Enzymatic hydrolysis of the disrupted cells using a mixture of cellulases and mannanases yielded up to 25% saccharification efficiency after 72 h. Acidic hydrolysis of undisrupted cells followed by enzymatic treatment yielded around 30% saccharification efficiency but was coupled with significant dilution of the resulting hydrolysate. Microalgal biomass hydrolysate produced was determined to have ~8.1 g L⁻¹ sugars and 2.5% (w/w) total carbon, as well as sufficient nitrogen and phosphorus content as a fermentation medium.

In this study, we explore the use of C. kluyveri in synthetic biofilms for the production of 1-butyrate and 1-hexanoate, investigating the impact of inoculation temperature during biofilm formation and the presence of yeast extract. Therefore, a novel synthetic biofilm reactor has been designed and constructed. Prior to investigating synthetic biofilms in this reactor, we carried out preliminary batch experiments in anaerobic flasks containing an inoculated agar hydrogel fixed at the bottom and overlaid medium. For the operation of the novel synthetic biofilm reactor, specific volumes of inoculated agar hydrogel were dispensed into a cylindrical mold with a diameter of 102 mm, forming the synthetic biofilm with a height of 4 mm, which was then transferred into the biofilm reaction chamber onto the support grid. The biofilm support grid separates the gas phase (CO₂, N₂) above the synthetic biofilm from the aqueous phase (medium) below. Our results show that C. kluyveri remains metabolically active at biofilm preparation temperatures of up to 45 °C, with extended lag phases observed at 70 °C. The synthetic biofilm demonstrated efficient chain elongation in batch processes, converting ethanol and acetate into 1-butyrate and 1-hexanoate, with final concentrations of 2.7 g L⁻¹ and 10.1 g L⁻¹, respectively, with yeast extract in the circulating liquid medium of the synthetic biofilm reactor setup. The maximum estimated space-time yields for 1-butyrate and 1-hexanoate, referenced to the biofilm volume, were 1.331 g L⁻¹ h⁻¹ and 4.947 g L⁻¹ h⁻¹, respectively. Experiments without yeast extract lead to final concentrations of 2.0 g L⁻¹ 1-butyrate, and 7.3 g L⁻¹ 1-hexanoate and maximum estimated space-time yields, referenced to the biofilm volume, were 0.332 g L⁻¹ h⁻¹ and 1.123 g L⁻¹ h⁻¹, respectively. The use of synthetic biofilms, even without yeast extract, eliminates the need for significant cell growth during chain elongation. However, product concentrations were lower without yeast extract.

Syngas fermentation in combination with chain elongation offers great promise for sustainable medium-chain fatty acid production. While immobilization has proven effective for stabilizing monocultures of C. kluyveri for chain elongation, its applicability to co-cultures involving C. carboxidivorans for simultaneous syngas fermentation remains unexplored. This study investigates the physiological compatibility of C. carboxidivorans with agar-based hydrogel immobilization and its co-cultivation potential with C. kluyveri in a synthetic dual-layer biofilm reactor. First, we conducted autotrophic batch fermentations using suspended and immobilized cells, proving metabolic activity similar for both. Applying different sulfur feeding rates, experiments showed best ethanol formation with C. carboxidivorans at increased sulfur feeding, enabling better conditions for chain elongation with C. kluyveri. In the synthetic dual-layer biofilm reactor, with the C. carboxidivorans biofilm in contact with the CO-containing gas phase above the C. kluyveri biofilm, the formation of 1-butyrate and 1-hexanoate was observed with product formation rates of 0.46 g L⁻¹ d⁻¹ 1-butyrate, and 0.91 g L⁻¹ d⁻¹ 1-hexanoate, respectively. The formation rate of 1-hexanoate in the dual-layer biofilm reactor was approximately 7.6 times higher than that reported with suspended cells in a stirred tank bioreactor. Spatial analysis revealed species-specific migration behavior and confirmed that C. carboxidivorans reduced local CO concentrations, improving the environment for C. kluyveri.