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A review of the various literature data for large-scale algae production costs is described. Costs were updated and recomputed in order to compare the different schemes. Total production costs of a nonprocessed biomass range from US$0.15 to US$4.0 kg(-1), according to various authors. Process performance hypotheses and proposed technologies are analyzed to explain these variations. A cost analysis for a tubular bioreactor system is then presented that shows that, assuming a productivity of 60 tons/ha yr, production costs would range from FF24 to FF29 kg(-1) for such a system. Operating costs as well as fixed charges account for approximately 50% of the cost. Parametric sensitivity of these costs is then analyzed: If productivity would be 30, 45, or 90 tons/ha yr, total cost would be around FF48, FF33 and FF19 kg(-1). Advantages and disadvantages of the proposed tubular technology are finally discussed.

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Packed-bed bioreactors (PBR) have proven to be efficient systems to culture mammalian cells at very high cell density in perfusion mode, thus leading to very high volumetric productivity. However, the immobilized cells must be continuously supplied with all nutrients in sufficient quantities to remain viable and productive over the full duration of the perfusion culture. Among all nutrients, oxygen is the most critical since it is present at very low concentration due to its low solubility in cell culture medium. This work presents the development of a model for oxygenation in a packed-bed bioreactor system. The experimental system used to develop the model was a packed-bed of Fibra-Cel disk carriers used to cultivate Chinese Hamster Ovary cells at high density ( approximately 6.1 x 10(7) cell/mL) in perfusion mode. With the help of this model, it was possible to identify if a PBR system is operated in optimal or sub-optimal conditions. Using the model, two options were proposed, which could improve the performance of the basal system by about twofold, that is, by increasing the density of immobilized cells per carrier volume from 6.1 x 10(7) to 1.2 x 10(8) cell/mL, or by increasing the packed-bed height from 0.2 to 0.4 m. Both strategies would be rather simple to test and implement in the packed-bed bioreactor system used for this study. As a result, it would be possible to achieve a substantial improvement of about twofold higher productivity as compared with the basal conditions.

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