Although primitive in design, open raceway ponds are still the predominant algaculture system for high-value added products and have been used for decades (Benemann and Oswald, 1996; Sheehan et al., 1998). The fact that raceway ponds are uncomplicated makes them less productive and offers little control over the culture parameters; however, the low cost of this low-tech cultivation system allows it to compete with complex photobioreactors (Gordon et al., 2007). The surface-to-volume ratio and corresponding light penetration in open ponds are not ideal. As a result, ponds can only support low culture densities; however, the ease of scaling production to industrial proportions (> 1 million liters per acre) justifies their seemingly low efficiency. The use of raceway ponds is also vindicated by their uncomplicated design, which makes them readily available for implementation and relatively simple to clean and maintain. While open ponds are cost effective, they do have a large footprint and contamination by local algal species and threat of algal grazers pose serious risks. Invasion by indigenous microorganisms may be protected against by the use of greenhouse enclosures or by growing algae that can withstand hypersaline environments, such as Dunaliella salina. For the purpose of biofuel production, however, the low areal productivities of ponds alone may not be able to provide the necessary biomass feedstock economically. Commercial scale microalgal biofuel facilities will likely rely on integrated systems of high efficiency photobioreactors to provide a dense inoculum for readily scalable raceway ponds (Huntely et al., 2007).

While genetic engineering approaches may improve the photosynthetic and biosynthetic capabilities of microalgae, many innovative methods exist for optimizing photoautotrophic culture conditions to accomplish the same goal of increased yield (Muller-Feuga, 2004). The breadth of chemical engineering knowledge being applied to photobioreactor (PBR) design in order to enhance light and nutrient availability represents an important advance in the field (Tredici and Zittelli, 1998; Miron et al., 1999), particularly for modular and scalable reactors (Janssen et al., 2003; Hu et al., 1996); however, the cost of these technologies remains the ultimate constraint on feasibility.

Photobioreactors aim to optimize many, if not all, of the culture parameters crucial to microalgal growth. One condition achieved in PBRs, but not raceway ponds, is turbulent flow to produce enhanced mixing patterns. By simply increasing the Reynolds number of these systems, the resulting fluid dynamics have a positive effect on nutrient mass transfer, light absorption, and temperature control (Ugwu et al., 2008). However, highly turbulent flow within complex geometries comes at the expense of the cells’ sensitivity to shear stress, which is one limitation of photobioreactor design. Another important consideration is the time scale over which the microalgae are transferred from the periphery of the bioreactor to the interior shaded region, as there exists a limit to the amount of light the cells can process before photoinhibiton occurs.

One of the most beneficial aspects of photobioreactors is the extended surface area achievable with tubular and flat-panel designs. This route to increased productivity takes advantage of allowing more algae to have contact with sunlight than an area of land would regularly allow with more basic cultivation systems; however, the additional cost of maintaining ideal temperatures and protecting these sometimes delicate devices from inclement weather pose some concern. Many of these nascent technologies depend entirely on the site of deployment and, as a result, require a great deal of customization (Janssen et al., 2003; Miron et al., 1999).

Some additional drawbacks of photobioreactors include the chemical gradients that can develop, particularly along tubular reactors. As a result of photosynthesis, a significant amount of oxygen can accumulate in these tubes and must be purged periodically. High concentrations of oxygen can both inhibit photosynthesis and, when combined with high irradiance, result in the formation of reactive oxygen species (ROS) (Tredici and Zittelli, 1998). These added difficulties contribute to the higher complexity and cost of photobioreactor operation. Some low-cost alternatives include vertical-column or hanging — bag bioreactors, which still provide a closed system for monocultures, with less control over culture parameters. These systems often rely on sparged air to provide both CO2 and mixing force, as in airlift bioreactors. The ability to strike a balance between cost and productivity is the major challenge of microalgal cultivation, especially for applications that require closed cultivation, as is the case with genetically modified microalgae.