This study reports on the optimization of the operating conditions using response surface methodology and a comparative study of three promising technologies of cell disruption (bead milling, microwaves and ultrasound) to increase the lipid extraction from Nannochloropsis oceanica, Nannochloropsis gaditana and Tetraselmis suecica. Central composite designs were used for the optimization of ultrasound and microwave processes. The performance of the cell disruption processes in breaking down microalgae cells is dependent on the strain of microalgae. Microwaves (91 °C for 25 min) were the most efficient for the recovery of lipids from N. oceanica, reaching a lipid content of 49.0% dry weight. For N. gaditana, ultrasound process (80% of amplitude for 30 min) was the most efficient in terms of lipid recovery (21.7% dry weight). The two aforementioned processes are ineffective in disturbing T. suecica whatever the operating conditions used. Only the bead milling process at low flow feed rate with 0.4 mm zirconia beads made it possible to extract 12.6% dry weight from T. suecica. The fatty acid profiles of N. oceanica and T. suecica are affected by the cell disruption process applied. The calculation of specific energy consumption has shown that this criterion should not be neglected. The choice of the most suitable cell disruption process can be defined according to numerous parameters such as the microalgae studied, the total lipid extracted, the fatty acids sought, or the energy consumption.

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Projections show that the cultivation of microalgae will extend to the production of bio-based compounds, such as biofuels, cosmetics, and medicines. This will generate co-products or residues that will need to be valorized to reduce the environmental impact and the cost of the process. This study explored the ability of lipid-extracted Chlorella vulgaris residue as a sole carbon and nitrogen source for growing oleaginous yeasts without any pretreatment. Both wild-type Yarrowia lipolytica W29 and mutant JMY3501 (which was designed to accumulate more lipids without their remobilization or degradation) showed a similar growth rate of 0.28 h−1 at different pH levels (3.5, 5.5, and 7.5). However, the W29 cell growth had the best cell number on microalgal residue at a pH of 7.5, while three times fewer cells were produced at all pH levels when JMY3501 was grown on microalgal residue. The JMY3501 growth curves were similar at pH 3.5, 5.5, and 7.5, while the fatty-acid composition differed significantly, with an accumulation of α-linolenic acid on microalgal residue at a pH of 7.5. Our results demonstrate the potential valorization of Chlorella vulgaris residue for Yarrowia lipolytica growth and the positive effect of a pH of 7.5 on the fatty acid profile.