Integrating wet stirred-bead milling for Tetraselmis suecica biorefinery: Operating parameters influence and specific energy efficiency

•Stirred bead milling extracts over 95% of proteins and 60% carbohydrates.•Optimal conditions were found for mid-range values of bead size and rotation speed.•The higher the microalgae concentration, the more efficient is the process.•Although extraction yields are similar, the pendular mode consumes the least energy. Stirred bead milling proved to be an efficient cell destruction technique in a biorefinery unit for the extraction of over 95 % of proteins and 60 % of carbohydrates from the green marine microalga Tetraselmis suecica. Optimum conditions, expressed in terms of metabolite yield and energy consumption, were found for average values of bead size and agitator rotation speed. The higher the microalgae concentration, up to 100 g.L−1, which is adequate for biofilm algae growth in an industrial unit, the more efficient the cell destruction process. Cell destruction rates and metabolite extraction yields are similar in pendular and recycling modes, but the pendular configuration reduces the residence time of the suspension in the grinding chamber, which is less costly. With regard to the cell destruction mechanism, it was concluded that bead shocks first damage cells by permeabilizing them, and that after a longer period, all cells are shredded and destroyed, forming elongated debris.