This dissertation describes research done on biofilm based algal cultivation systems. The system that was developed in this work is the revolving algal biofilm cultivation system (RAB). A raceway-retrofit, and a trough-based pilot-scale RAB system were developed and investigated. Each of the systems significantly outperformed a control raceway pond in side-by-side tests. Furthermore the RAB system was found to require significantly less water than the raceway pond based cultivation system. Lastly a TEA/LCA analysis was conducted to evaluate the economic and life cycle of the RAB cultivation system in comparison to raceway pond. It was found that the RAB system was able to grow algae at a lower cost and was shown to be profitable at a smaller scale than the raceway pond style of algal cultivation. Additionally the RAB system was projected to have lower GHG emissions, and better energy and water use efficiencies in comparison to a raceway pond system.

Furthermore, fundamental research was conducted to identify the optimal material for algae to attach on. A total of 28 materials with a smooth surface were tested for initial cell colonization and it was found that the tetradecane contact angle of the materials had a good correlation with cell attachment. The effects of surface texture were evaluated using mesh materials (nylon, polypropylene, high density polyethylene, polyester, aluminum, and stainless steel) with openings ranging from 0.05–6.40 mm. It was found that both surface texture and material composition influence algal attachment.