1. Introduction
The cultivation of mushrooms can be traced back to as early as 600 BC, starting with wood ear mushrooms (
Auricularia auricula), cultivated on logs in China. Around 60 strains are commercially grown, with a select 10 produced on an industrial scale [
1]. The 1980s was a pivotal period marked by the introduction of indoor cultivation in controlled environments, which led to a significant rise in global mushroom production [
2]. Recent advancements indicate that interconnected smart farms represent the next frontier for optimizing these cultivation spaces [
3,
4]. Such interconnectivity enables real-time data exchange, thus allowing the integration of various agricultural processes to attain ecological and economic targets [
5,
6].
As such, there is untapped potential to implement solutions enabling the circular economy. One example of this concept is the cultivation of mushrooms and leafy greens in controlled environment agriculture (CEA). This combination can be synergistic, as the CO
2 emitted by mushrooms through respiration becomes a valuable resource for improving the growth environment of leafy greens, thereby enhancing photosynthesis [
7,
8]. This synergy warrants consideration, as CO
2 enrichment typically stems from non-environmentally friendly fossil fuel combustion or costly pure liquefied CO
2 [
9].
Enriching the leafy green environment with CO
2 released from mushroom growth has been studied in controlled environment experiments on bench tests with shiitake [
10] and king oyster [
7,
11] strains combined with lettuces. These studies consistently demonstrated the feasibility of CO
2 exchange between the two crops. Still, the results were limited to the fructification growth stage of mushrooms, leaving the incubation stage, which represents about one-third of the life cycle production of mushrooms [
12], unexplored.
Leafy greens grown in CEA with artificial lighting generate heat, often necessitating year-round cooling [
13]. Similarly, mushroom substrates in CEA are exothermic [
12,
14,
15]. However, all studies on the synergies between mushrooms and leafy greens have overlooked the thermal interactions between the two crops. This oversight is significant, as heat exchanges between these crops can critically impact the energy efficiency of a synergistic system. Factors such as crop strains, temperature and humidity setpoints, lighting, and local climate play a role. Integrating both CO
2 emission and heat exchange rates as part of the analysis would offer a more realistic picture of the benefits of this synergy, as illustrated in
Figure 1.
To develop a comprehensive CO
2 and energy exchange model between mushrooms and leafy greens, specific data on CO
2 emission and heat exchange rates for shiitake and oyster mushrooms are essential but currently lacking. Notably, mushrooms generate significant heat during the incubation stage due to thermogenesis [
14]. Koncsag & Kirwan [
15] quantified the heat exchange rate for oyster mushrooms during this stage, but such data are missing for shiitake. Despite the interest in mushroom cultivation, there are few quantitative analyses on their CO
2 emission rates [
15]. In the 1970s, a theoretical model describing mycelium growth and CO
2 emission rate was developed based on the dried mass of mycelium and mushroom fruit [
16]. Recently, Jung & Son [
17] introduced an empirical model adapted from one proposed by Chanter & Thornley, which predicts the CO
2 emission rates of king oyster mushrooms during the fructification stage considering indoor temperature and time. The results indicated that CO
2 emission rates increased exponentially with time and linearly with temperature. However, the CO
2 model was limited to king oyster mushrooms, no model was proposed for the incubation stage, and no information related to the heat exchange rate was documented. No CO
2 emission rate models appear to exist for shiitake, but a study has been conducted across various shiitake strains that reported the CO
2 emitted for both the incubation and fructification stages at 24 °C [
18]. Unlike oyster mushrooms, shiitake mushrooms are generally grown at lower temperatures, such as 21 °C [
12]. Opting for a production temperature of 21 °C could prove more advantageous for synergistic cultivation with leafy greens, as it would result in lower cooling loads for the leafy greens when grown in a controlled environment [
13]. Moreover, developing a model that provides the CO
2 exchange rate of a typical full-scale incubation chamber housing a variety of mushroom genera and strains at diverse growth stages would offer valuable complementary data to small-scale experiments, as is often the case in commercial mushroom farms [
12].
The experimental results aim to advance sustainability in mushroom cultivation by investigating CO2 emission and heat exchange rates, specifically focusing on oyster and shiitake mushrooms and their interaction with leafy greens. They provide valuable data on the CO2 emission and thermal exchange rates of shiitake mushrooms at lower indoor temperatures, addressing gaps in the existing literature. The study also evaluates CO2 emission rates in mixed-genus incubation chambers, developing a temperature-based emission model. These insights are crucial for developing global CO2 emission and energy model for mushroom and leafy green, representing the next step of quantifying the benefits of synergetic cultivation between these two crops.
2. Materials and Methods
This study is based on experiments in two distinct testing spaces: (1) a controlled small-scale test bench and (2) a full-scale incubation chamber of a mushroom farm. These spaces were used to conduct three experiments to develop an empirical mass and energy balance model for mushrooms. This section provides an overview of the testing spaces, outlines the experimental setup, and details the model’s development and validation process. The equations used to convert CO2 emission data from existing literature into useful metrics for comparison with the experimental results are also introduced.
2.1. Average CO2 Emission Rates
In commercial mushroom cultivation, a common practice is to adopt staggered production or diversified growing techniques to maintain a steady harvest. This requires carefully timing the inoculation, incubation, and fructification stages across different mushroom batches, ensuring a continuous harvesting cycle. As a result, there is a mix of growth stages at any given time on the farm. An average CO
2 emission rate for both the incubation stage and fructification stage is used to assess this strategy. The current literature on CO
2 emission rates within the mushroom growth cycle is limited. Existing studies have either aggregated the CO
2 emission rates over time, as shown in
Table 1, or have developed CO
2 emission rates using predicting models at specific times using Equations (1) and (2).
Here,
and
are the CO
2 emission rate of 0.57 kg of king oyster substrate in the fructification stage before and after tinning, respectively [μg CO
2·s⁻¹·],
is the indoor air temperature [°C], and
is the number of days since the start of the fructification stage. In the model, Equation (1) was used from
1 to 12, and Equation (2) was used from
12 to 17 [
19].
In studies that present cumulative CO
2 emission rates over a specific growth cycle and period, the average CO
2 emission rate was calculated by dividing the total emitted CO
2 by the duration of the experiment and substrate mass, as described in Equation (3):
Here
is the average CO
2 emission rate of substrate [μg CO
2·s
−1·kg
sub−1],
is the mass of CO
2 emitted during the specific period [μg CO
2],
is the duration of the experiment [s], and
is the substrate mass [kg].
To determine the average CO
2 emission rate using Equations (1) and (2), the average CO
2 emission rate at a specific indoor temperature throughout the entire cycle was calculated using Equation (4), where
and
represent the days of the cycle before and after thinning, respectively.
2.2. Description of the Testing Spaces
The following section presents an in-depth overview of the two testing spaces used in the study: the small-scale (SS) test bench and the full-scale (FS) incubation chamber. The section details the specifications and equipment of these spaces. These spaces were equipped with data acquisition systems for monitoring the indoor environmental conditions, as described in
Table 2.
2.2.1. Small-Scale (SS) Test Bench
The small-scale test bench is a 3.02 m × 2.44 m × 1.97 m (volume of 14.5 m
3) space located within a building maintained at an indoor temperature of approximately 20–21 °C (
Figure 2a). The walls, floor, and ceiling of the test bench were constructed from polyurethane-insulated panels with an overall U-value of 0.12 W·(K·m
2)
−1, a thermal capacity of 1000 J·(kg·K)
−1, and a density of 113.17 kg·m
−3. The surfaces were covered with plastic water-repellent panels to prevent water vapor diffusion, with an airtightness of 3.7 ACH @ 50 Pa. The conditions inside the small-scale test bench were controlled using heating, ventilation, and air conditioning (HVAC) equipment, with a return air duct area (
) of 0.124 m
2. The sensor locations in the test bench are illustrated in
Figure 2b. Two different air loop configurations are possible: an open-loop (OL) and closed-loop (CL). For the closed-loop (CL) configuration, the HVAC equipment was turned off, allowing the indoor conditions (temperature, humidity, and CO
2 concentration) to increase inside the chamber, enabling the use of differential equations to estimate the CO
2 emission and heat exchange rates.
2.2.2. Full-Scale (FS) Incubation Chamber
The full-scale incubation chamber of a mushroom farm located in Quebec, Canada (
Figure 3a) was used as a second testing space. The incubation chamber has a volume of 56 m
3, where the indoor air temperature and CO
2 concentration are regulated by an HVAC system, which has a return air duct (
) with an area of 0.025 m
2.
The test bench has an Arduino Mega microcontroller data acquisition system connected to the farm’s Ethernet network. Temperature, humidity, and CO
2 concentration readings of the supply air and return air of the incubation chambers were recorded as illustrated in
Figure 3b and detailed in
Table 2. Only an open-loop (OL) configuration is possible in this space.
2.3. Description of the Experiments
For all experiments, each substrate bag consisted of the following mass proportions: 70% wood sawdust, 20% bran, 10% mycelium on grain and water to saturation, with an average weight of 3 kg per bag. During incubation, bags were kept at indoor temperatures of 18–24 °C, CO2 concentrations of 800–1000 ppm, and without relative humidity control. For each experiment, the colonization ratio was about 50%, representing the real-life operation of an incubation chamber. The substrate colonization ratio is the fraction of substrate bags that are fully colonized, i.e., the incubation stage is completed and the substrate is ready to be transferred to the fructification stage. A substrate bag is determined to be fully colonized by visual inspection when the outer surface of the substrate was totally white. The two testing spaces were used to conduct three distinct experiments, all in the incubation stage of mushroom production: SS-OL-53%, SS-CL-53%, and FS-OL-44%, as described below.
SS-OL-53%: This experiment determined the average CO2 emission rate of Shiitake mushrooms incubating at an indoor temperature of 21 °C. This was achieved using an open-loop (OL) ventilation configuration where the supply ( and return air (CO2 concentrations were measured as well as the return air speed (). Data were collected every minute and averaged over 30 min for 14 h. During this experiment, there is 215 kg of shiitake substrate, 53% of which is fully colonized.
SS-CL-53%: This experiment was used to evaluate the heat exchange rate of Shiitake substrate in incubation and to validate the CO2 emission rate results of experiment SS-OL-53%. This was achieved using a closed-loop (CL) ventilation configuration, i.e., no forced airflow, and all air dampers were closed. Thus, the CO2 and heat rise over time in the CL configuration. Data were analyzed when steady-state conditions were attained and stopped when either the CO2 concentration ( reached 2000 ppm (probe saturation value) or the indoor temperature ( reached 24 °C. Except for the ventilation configuration, this setup was identical to SS-OL-53%, a small-scale test bench with 215 kg of 53% colonized shiitake substrate.
FS-OL-44%: This experiment was conducted in a full-scale incubation chamber with mixed substrate strains and aims to develop a CO2 emission rate model based on the indoor temperature. This was achieved using an open-loop (OL) ventilation configuration. The difference in CO2 concentration between the supply ( and return air ( was used to complete the emission rate calculations. Data were recorded every 5 min and averaged over an hour for 75 h. Data recorded during and for an hour following the presence of workers in the chamber were excluded. During this experiment, there was 1827 kg of mixed substrate (46% shiitake, 44% oyster, 10% lion’s mane), with 44% fully colonized.
2.4. Experimental Model Development
The equations presented in this section quantify the CO2 emission and heat exchange rates based on the experimental data.
2.4.1. CO2 Emission Rate
The CO
2 emission rate, which indicates the respiratory activity of the mushroom substrate, is calculated using approaches derived from indoor air quality science [
20]. A conversion factor k [
7] is included to fit with experimental conditions. For the open-loop (OL) experiments, the steady-state CO
2 balance between the return and supply air in the chamber was estimated using Equation (5). For the closed-loop (CL) experiment, SS-CL-53%, a differential equation comparing the CO
2 concentration at the beginning and end of the experiment was used instead, as described by Equation (6).
Here,
is the CO
2 emission rate of substrate [μg CO
2·s
−1·kg
sub−1],
and
are the CO
2 concentration of supply air (S/A) and return air (R/A) from the test bench, respectively [μmol·mol
−1],
equals to 1830 and is a unit conversion factor from CO
2 μmol·mol
−1 to μg CO
2·m
−3 at 20 °C,
is the return air speed [m·s
−1],
is the return duct area [m
2], and
is the substrate mass [kg].
Here,
is the mass of CO
2 in the test bench [μg CO
2·kg
sub−1],
is the time [s],
and
are the CO
2 concentration at the beginning and the end of the experiment, respectively [μmol·mol
−1],
is the test bench volume [m
3], and
and
are the time at the beginning and the end of the experiment, respectively [s].
Since the full-scale (FS) test bench FS-OL-44% is an existing incubation chamber of a mushroom farm with an average weekly production of 560 kg, it experienced fluctuations in indoor air temperature. Considering that the CO
2 emission rate of mycelium increases linearly according to temperature [
17], linear regression was used to represent the relationship between CO
2 emission rate, return air temperature, and substrate mass (Equation (7)). To ensure unbiased results, all measurement time stamps were randomly shuffled using the Mersenne Twister algorithm [
21]. The regression was constructed using the first two-thirds of the data points, while the last third was used to validate the accuracy of the regression, as follows:
Here,
is the return temperature of the test bench [°C], and
, are regression coefficients [dimensionless].
2.4.2. Heat Exchange Rate
The heat exchange rate quantifies the rate of thermal energy transfer between the mushroom substrate and its environment. This is estimated using equations typically used to describe HVAC systems [
20]. The heat exchange rate was calculated solely for the small-scale (SS) experiments. It was estimated using differential Equation (8), which calculates the difference in enthalpy at the test beginning and ending.
Here,
is the heat exchange rate from the mushroom substrate [W],
is the specific enthalpy [kJ·kg
da−1],
equals 1.19 and is the average air density during the experiment [kg·m
−3], and
and
are the specific enthalpies at the beginning and at the end of the experiment, respectively, estimated using Equation (9).
Here,
is the specific enthalpy of dry air [kJ·kg
da−1],
is the specific enthalpy for saturated water vapor [kJ·kg
da−1], and
is the humidity ratio [kg
w·kg
da−1]. The humidity ratio is computed using Equation (10), as follows:
Here,
is the relative humidity expressed as a fraction,
is the saturation pressure [Pa], and
is the atmospheric pressure [Pa]. The saturation pressure over liquid water is given by Equation (11) and
to
are listed in
Table 3.
Here,
is the absolute temperature [
].
2.4.3. Full-Scale Experimental Model Validation
The data collected during the FS experiment FS-OL-44% were divided into two subsets: the first two-thirds were used to create the regression, while the last third was used to validate the regression model. The regression was checked using the
p-value and R
2. A
p-value less than 0.05 indicates a satisfactory level of confidence, and the closer R
2 is to 1, the more the variance in the CO
2 emission rate is explained by the variation of the indoor air temperature. Also, the mean relative deviation (MRD), defined according to Equation (12), was used to assess the accuracy between the measured data and the estimated CO
2 emission rate using the proposed model [
22]. A lower MRD indicates that the model’s predictions closely match the measured values. A MRD of less than 10% signifies a strong correlation, while a MRD within the 10–20% range represents average accuracy. Conversely, a MRD exceeding 20–30% is deemed insufficient.
Here,
is the mean relative deviation,
is the sample size,
are the measured data from the validation sample, and
are the values estimated from the model.