Life Cycle Assessment of Innovative Magnetic Harvesting and Particle Detachment for Sustainable Chlorella vulgaris Recovery

Harvesting remains one of the main bottlenecks in microalgae-based technologies. Although microalgae hold great promise for industrial biotechnology, their growth in dilute suspensions makes biomass recovery challenging. Conventional harvesting methods are often energy-intensive and costly, limiting large-scale implementation. This study applies a life cycle assessment (LCA) to evaluate the environmental performance of a laboratory-scale magnetic harvesting process of Chlorella vulgaris (C. vulgaris) using Fe3O4 microparticles in combination with polyaluminum chloride (PAC) and polyacrylamide (PAM), followed by magnetic oscillation for particle detachment and subsequent reuse. Electricity consumption was identified as the dominant environmental hotspot across most impact categories, with the detachment step accounting for nearly two-thirds of the total energy demand, a step often overlooked in previous LCA studies. The global warming potential (GWP) is consistent with typical laboratory-scale assessments and is mainly driven by energy inefficiencies associated with small processing volumes. The values obtained and the scale-up literature indicate that further optimization and future industrial-scale production will decrease these values into a realistic and competitive range. Sensitivity analysis showed that replacing grid electricity with photovoltaic power significantly reduces environmental impacts. The use of NaOH as a reagent also contributed substantially to environmental impacts. Reusing magnetic particles (4 cycles) reduced material resource depletion by up to fourfold, which is a very relevant result bearing in mind the principles of sustainability and circularity.