Novel Process Configuration of Photobioreactor and Supercritical Water Oxidation for Energy Production from Microalgae

This study presents the first comprehensive investigation of direct supercritical water oxidation (SCWO) of microalgae biomass integrated with photobioreactor oxygen recovery for sustainable energy production. Laboratory-scale experiments were conducted on Nannochloropsis gaditana at optimized conditions (650°C, 24 MPa, 1 min residence time), achieving extraordinary conversion efficiency of 99.99% at biomass concentrations as low as 0.5 wt%. Process simulation using Aspen Plus demonstrated that this integrated photobioreactor-SCWO system can recover oxygen produced during photosynthesis, reducing compressor energy demands by 10–15% compared to conventional air-fed systems. The coupled system achieved net thermal power outputs of 47–66 kW from a 1 kg/min microalgae feed at 5–10 wt% biomass concentration, corresponding to an overall system thermal efficiency of approximately 18%. CO2 recovery via mono-ethanolamine absorption enabled 70–80% carbon cycle closure, while simultaneous nutrient recycling through the aqueous phase supports sustainable circular economy principles. This coupled photobioreactor-SCWO process represents an efficient pathway for energy recovery from wet microalgae biomass, eliminating the energy-intensive drying requirement (typically 60–70% of conventional processing energy) and achieving complete mineralization of organic compounds. The system demonstrates technical and energetic viability for scaling to pilot demonstration scale.