Heterotrophic fermentation of microalgae is a key route for biodiesel commercialization, but its economic viability is hampered by high carbon source costs and the intrinsic “carbon partitioning” problem, where carbon is preferentially converted into starch rather than the target product, lipids. Although studies have blocked starch synthesis to enhance lipid yield, this work has been largely confined to the laboratory flask scale, leaving performance and molecular mechanisms under simulated industrial high-density fermentation conditions as a critical knowledge gap. In this study, a starch-synthesis-deficient Chlorella vulgaris mutant SDM4 was screened via chemical mutagenesis. It was systematically compared with the wild-type (WT) in a 7-L bioreactor using a fed-batch heterotrophic strategy to evaluate its growth characteristics, biochemical composition, and substrate conversion efficiency. Finally, comparative transcriptomics was employed to dissect the underlying molecular regulatory network of its high-lipid phenotype. A stable mutant, SDM4, with nearly complete blockage of starch synthesis, was successfully obtained. In the 7-L bioreactor, SDM4 exhibited a final triacylglycerol (TAG) content of 16.9% of dry weight, 1.8-fold higher than that of the WT. More importantly, the glucose-to-TAG conversion yield increased from 0.038 g g−1 in the WT to 0.059 g g−1 in SDM4. Consequently, the substrate conversion cost was reduced by 36.64%, demonstrating significant economic potential. Transcriptomic analysis revealed a sophisticated synergistic “Push-Pull” mechanism: the starch synthesis pathway was significantly suppressed (the “Pull”), while the glycolysis, fatty acid synthesis, and TAG assembly pathways were systematically activated (the “Push”), thereby efficiently reprogramming the carbon metabolic flux towards lipid synthesis. This study not only presents a promising microalgal mutant, SDM4, with excellent production performance and economic benefits under simulated industrial conditions but also, for the first time, systematically unveils the global metabolic reprogramming of such a mutant in a high-density heterotrophic environment. These findings provide a critical theoretical basis and key genetic targets for the future rational design of efficient microalgal cell factories.
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