Industrial production of novel microalgal isolates is key to improving the current portfolio of available strains that are able to grow in large-scale production systems for different biotechnological applications, including carbon mitigation. In this context, Tetraselmis sp. CTP4 was successfully scaled up from an agar plate to 35- and 100-m3 industrial scale tubular photobioreactors (PBR). Growth was performed semi-continuously for 60 days in the autumn-winter season (17th October – 14th December). Optimisation of tubular PBR operations showed that improved productivities were obtained at a culture velocity of 0.65–1.35 m s−1 and a pH set-point for CO2 injection of 8.0. Highest volumetric (0.08 ± 0.01 g L−1 d−1) and areal (20.3 ± 3.2 g m−2 d−1) biomass productivities were attained in the 100-m3 PBR compared to those of the 35-m3 PBR (0.05 ± 0.02 g L−1 d−1 and 13.5 ± 4.3 g m−2 d−1, respectively). Lipid contents were similar in both PBRs (9–10% of ash free dry weight). CO2 sequestration was followed in the 100-m3 PBR, revealing a mean CO2 mitigation efficiency of 65% and a biomass to carbon ratio of 1.80. Tetraselmis sp. CTP4 is thus a robust candidate for industrial-scale production with promising biomass productivities and photosynthetic efficiencies up to 3.5% of total solar irradiance.

Biomass harvesting is one of the most expensive steps of the whole microalgal production pipeline. Therefore, the present work aimed to understand the effect of salinity on the growth performance, biochemical composition and sedimentation velocity of Tetraselmis sp. CTP4, in order to establish an effective low-cost pilot-scale harvesting system for this strain. At lab scale, similar growth performance was obtained in cultures grown at salinities of 5, 10 and 20 g L -1 NaCl. In addition, identical settling velocities (2.4–3.6 cm h -1 ) were observed on all salinities under study, regardless of the growth stage. However, higher salinities (20 g L -1 ) promoted a significant increase in lipid contents in this strain compared to when this microalga was cultivated at 5 or 10 g L -1 NaCl. At pilot-scale, cultures were cultivated semi-continuously in 2.5-m 3 tubular photobioreactors, fed every four days, and stored in a 1-m 3 harvesting tank. Upon a 24-hour settling step, natural sedimentation of the microalgal cells resulted in the removal of 93% of the culture medium in the form of a clear liquid containing only vestigial amounts of biomass (0.07 ± 0.02 g L -1 dry weight; DW). The remaining culture was recovered as a highly concentrated culture (19.53 ± 4.83 g L -1 DW) and wet microalgal paste (272.7 ± 18.5 g L -1 DW). Overall, this method provided an effective recovery of 97% of the total biomass, decreasing significantly the harvesting costs.

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