José C. M. Pires

Chlorella vulgaris, a widely cultivated microalgae with diverse commercial applications, faces challenges in economic viability and scalability during the crucial biomass harvesting step. This study explores chemical flocculation followed by sedimentation as a cost-effective solution. Optimization was performed for three flocculants (chitosan, aluminum sulfate, and ferric sulfate), with experiments determining optimal pH and dosage ranges (10–200 mg·L−1). A 24-full factorial design optimized flocculant dosage, settling time, rapid mixing time, and slow mixing time, analyzing their effects on harvesting efficiency through empirical models. The optimal dosage ranges were 50–200 mg·L−1 for aluminum sulfate and 150–200 mg·L−1 for ferric sulfate at pH 9, and 10–50 mg·L−1 for chitosan at pH 5. Empirical models exhibited high fitting performance (R2 > 95%) and predictive capability (predicted R2 > 96%). All flocculants demonstrated high efficiencies (98.4–99.5%), with inorganic types requiring fast and slow mixing phases, while chitosan achieved optimal results without the need for both mixing phases, suggesting potential industrial advantages in time and energy efficiency for microalgae harvesting.