An integrated system combining ultrasound-intensified outdoor cultivation of Botryococcus braunii with in situ magnetic harvesting of the algal cells was developed. The algal cells were cultivated in 200 L plastic bag reactors, and seven five-minute ultrasonic treatments at a four-day interval using a fixed frequency of 40 kHz and a total power of 300 W improved algal cell biomass and hydrocarbon productivity. The algal cells were harvested using functional magnetic particles and a magnetic separator, and a recovery efficiency of 90% was obtained under continuous operation at a flow rate of 100 mL/min using the in situ magnetic separation system. The overall production cost using the integrated system was US$ 25.14 per kilogram of B. braunii dry biomass. The system developed in this study provides a base for the industrial production of B. braunii. (C) 2014 Elsevier Ltd. All rights reserved.