Microalgae are increasingly being used for capturing carbon dioxide and converting it into valuable metabolites and biologically active compounds on an industrial scale. The efficient production of microalgae biomass requires the optimization of resources, including CO₂. Here, we estimated the productivity of Chlorella sorokiniana IPPAS C-1 depending on CO₂ concentrations and the ventilation coefficient of the gas-air mixture (GAM) in flat-panel photobioreactors (FP-PBRs) at laboratory (5 L) and pilot (18 L) scales. For the laboratory scale, the PBRs operated at 900 µmol quanta m⁻² s⁻¹ and 35.5 ± 0.5 °C; the optimal CO₂ flow rate was estimated at 3 mL CO₂ per 1 L of suspension per minute, which corresponds to 1.5% CO₂ in the GAM and an aeration rate of 0.2 vvm. These parameters, being scaled up within the pilot PBRs, resulted in a high specific growth rate (µ ≈ 0.1 h⁻¹) and high specific productivity (P_sp ≈ 1 g dw L⁻¹ d⁻¹). The principles of increasing the efficiency of the intensive cultivation of C. sorokiniana IPPAS C-1 are discussed. These principles are relevant for the development of technological regimes for the industrial production of Chlorella in flat-panel PBRs of various sizes.

Microalgae biotechnology is increasingly applied across diverse fields, from food and medicine to energy and environmental protection, with strain selection being crucial for both target product accumulation and scalability potential. In this study, we for the first time assess the scalability of two new promising green microalgae strains, Neochlorella semenenkoi IPPAS C-1210 and Desmodesmus armatus ARC-06, in 5-L flat-panel photobioreactors. The growth characteristics of each culture, along with their biochemical composition and CO₂ utilization efficiency, were examined and compared to the well-studied model strain Chlorella sorokiniana IPPAS C-1. While C-1 achieved the highest biomass concentration (7.1 ± 0.4 g DW L⁻¹ by day 8) and demonstrated superior specific productivity (1.5 ± 0.1 g DW L⁻¹ d⁻¹) and CO₂ utilization efficiency (average 25.4%, peaking at 34% on day 3), ARC-06 accumulated the highest starch content (51% of DW), twice that of C-1. Strain C-1210 showed intermediate performance, reaching 6.8 ± 0.8 g DW L⁻¹ biomass with a CUE of 22.7%, whereas ARC-06 had the lowest CUE (12.8%). These results, combined with proposed cultivation optimization strategies, provide a foundation for scaling up N. semenenkoi and D. armatus production in industrial flat-panel PBR systems.

The industrial cultivation of microalgae for high-value products faces significant challenges, particularly in maintaining long-term, cost-effective operations. Semi-continuous cultivation presents a promising solution to this problem. In this study, the green alga Chlorella sorokiniana IPPAS C-1 was cultivated in a flat-panel 5 L photobioreactor under optimized conditions, with three biological replicates. We evaluated batch mode against three semi-continuous dilution fractions (50%, 75%, and 87.5%). The 75% dilution fraction demonstrated superior performance, achieving the highest biomass productivity with an average specific productivity of 1.36 g DW L⁻¹ day⁻¹ over seven harvest cycles. Furthermore, this regime ensured stable biochemical composition—including proteins, lipids, carbohydrates, and pigments—as well as a consistent lipid profile and sustained photosynthetic activity throughout the cultivation. These findings are useful for the development of scalable and efficient technological protocols for the industrial production of Chlorella in flat-panel photobioreactors.