0960–3085/00/$10.00+0.

00
# Institution of Chemical Engineers
Trans IChemE, Vol 79, Part C, December 2001

THE EFFECT OF THE TUNING PARAMETERS ON THE

PERFORMANCE OF THE PARAMETRIC AND
NONPARAMETRIC MODEL BASED CONTROL METHODS
FOR GROWTH MEDIUM TEMPERATURE OF BAKER’S
YEAST PRODUCTION
Ï LU2 and M. ALPBAZ2
N. BURSALI1 , S. ERTUNÇ 2 , B. AKAY2 , V. PAMUK3 , H. HAPOG
1
Department of Health, Yenimahalle Municipality, Ankara, Turkey
2
Department of Chemical Engineering, Ankara University, Turkey
3
Department of Chemical Engineering, Gazi University, Ankara, Turkey

I
n this study, nonparametric and parametric model based control methods were applied in
the control line in order to control the growth medium temperature of aerobic baker’s yeast
production in a batch bioreactor, and the performance was compared experimentally and
theoretically. For a non-parametric model, an experimental reaction curve was found by
performing the open-loop step test. The reaction curve was presented by the Ž rst order dead
time model to represent the dynamic behaviour of the reactor. An Internal Model Control
(IMC) system based on a non-parametric model, has been used to track the temperature of the
reactor mixture. The simulation program is used to calculate the parameters of the parametric
Controlled Auto Regressive Moving Average (CARMA) model for Self-Tuning PID (STPID)
control. The parameters of the CARMA model are calculated using Bierman algorithm by
applying Pseudo Random Binary Sequence (PRBS).
In the Ž rst part of the control work, a simulation program was used to observe the
performance of IMC and STPID control systems by calculating the Integral Square Error
(ISE) values. Two different kinds of operating conditions, such as load and set point effects
were applied to test the control performance for servo and regulatory behaviours. The Ž lter
time tf for IMC and the Ž rst parameter of Tailoring polynomial for STPID were used as tuning
parameters. In addition, PID control system performance was compared with both parametric
and non-parametric control systems.
In the second part of the control work, the growth medium temperature of aerobic baker’s
yeast production was controlled experimentally by using IMC and STPID systems in an on-line
computer controlled batch bioreactor. Non-parametric and parametric models for both control
systems were tested by considering the reaction heat as a load effect. The heat input given from
the immersed heater was chosen as the manipulated variable. It was observed that IMC was
more effective than STPID and PID methods.

Keywords: Internal Model Control; Self Tuning PID control; pole placement technique;
Integral Square Error criteria; Baker’s yeast; bioprocess control.

INTRODUCTION In recent years, more effective and modern control

Bioprocesses use enzymes or microorganisms as biocata-
lysts to convert one compound into one or more products. It
is also possible to produce enzymes or microorganisms as
products. Whatever the purpose of operating bioprocesses, it
is essential to obtain maximum volumetric productivity and
maximum cell yield. Additionally, since the biocatalysts are
very sensitive to changes occurring in their environment, it
is important to control the applications of the operating
parameters1. These parameters can be dissolved oxygen2,
pH3, temperature4 and substrate concentration5 in the
culture medium.
techniques have been developed and applied both to
bioprocesses6 and chemical processes7–8. Some of these
control techniques use IMC systems. The IMC system is
based on the non-parametric model, and the STPID control
on the parametric model. The control performance can be
affected by the choice of many steps. These are the type of
system model, model and tuning parameters etc. The para-
meters of non-parametric and parametric models are calcu-
lated by using different disturbance effects and identiŽ cation
algorithms. The parametric models are constructed, gener-
ally, by using the discrete polynomial model. The choice of
the order of the polynomial is very important. The PRBS

242
 EFFECT OF TUNING PARAMETERS ON MODEL CONTROL METHODS
signal is generally applied to obtain input–output data from
process. Different kinds of identiŽ cation algorithm such as
Bierman9, Levenberg-Marquard10, Genetic algorithm11 can
be used in the calculation of the model parameters. For non-
parametric models, the parameters of these models can be
calculated by using related curves such as the reaction curve
and Bode diagrams. The reaction curve is one of the non-
parametric model and it is obtained from the step change
given to the manipulated variable. It is very important to
deŽ ne the time constant and dead time. The slope of rising
curve and the second steady-state condition must be chosen
very carefully in deŽ ning the parameter values. The system
model parameters can be changed using several methods.
However, in some cases, instead of changing parameters
continuously, the tuning parameters can compensate the
changes in the dynamic conditions of the system.
In this work, a well known microorganism, particularly
used in the food industry, S.cerevisiae (Baker’s yeast), was
used. The temperature of the growth medium in a batch
bioreactor was controlled using IMC and STPID algorithm.
An experimental step test was used to deŽ ne the time constant
and dead time of Ž rst order transfer function for the nonpara-
metric model. These parameters and models were used in the
IMC control system. As well as constant values of para-
meters, Ž lter time tf was chosen as a tuning parameter of the
IMC control system. The best value of Ž lter time was
calculated according to time variation of the reactor tempera-
ture. In the parametric model, parameters were calculated
using the PRBS signal and Bierman algorithm. According to
the system dynamics, a second order CARMA model was
used for STPID control. Proper values of magnitude and the
time step of the PRBS signal were chosen. The parameters of
the CARMA model were used in the STPID control algo-
rithm. The Ž rst parameter of the Tailoring polynomial was
used as a tuning parameter for STPID control. The best value
of the t1 parameter was found by calculating the performance
index. Theoretical and experimental control work were
realized to observe controller performance. ISE values were
computed for the closed-loop process output. In the theore-
tical work, the simulation program which had energy and
mass balance equations together with control algorithms, was
used to calculate the control performance. Load and set point
effects were examined to observe the control performance for
servo and regulatory behaviours.
MATERIALS AND METHODS
The yeast S.cerevisiae NRRL-Y-567 obtained from the
Northern Regional Research Center, ARS culture collection
(Peoira, IL) was used in this study. The stock cultures were
maintained on agar slants containing 2% glucose, 0.6%
yeast extract, 0.3% K2HPO4, 0.335% (NH4)2SO4, 0.376%
NaH2PO4, 0.052% MgSO4.7H2O, 0.0017% CaCl2.4H2O,
2% agar.
The cells growing on the newly prepared slants were
inoculated into the same liquid medium and cultivated at
30° C for 24 h. Cells which were in the exponential growth
phase were inoculated from the seed culture into the growth
medium containing 2% glucose, 0.6% yeast extract, 0.3%
K2HPO4, 0.335% (NH4)2SO4, 0.376% NaH2PO4, 0.052%
MgSO4.7H2O, 0.0017% CaCl2.4H2O and 0.2 ml antifoam
A. 1:10 inoculum was used for optimization experiments.
Glucose, as a carbon and energy source, and salt solution
Trans IChemE, Vol 79, Part C, December 2001
243
were separately sterilized in an autoclave. The bioreactor
and other auxiliary equipment were sterilized with ethanol.
Air was continuously supplied to the bioreactor by a sparger
after passing through an air rotameter and microbiological
Ž lter. Cell concentration was determined turbidimetrically at
580 nm with a Shimadzu (Tokyo, Japan) model UV-160A
spectrophotometer.
A 2 l bioreactor with a cooling jacket was used. Sensors
were placed in the reactor to measure pH, temperature and
dissolved oxygen in the culture medium. Air was continu-
ously fed into the bioreactor by passing through a rotameter
and microbiological Ž lter at a rate of 0.83 vvm. Agitation
was supplied using turbine impeller and studied at 300 rpm.
An immersed heater for heating the culture medium to
the desired operating temperature was also placed in the
bioreactor.
On-line computer control was used to control the growth
medium temperature. By using a thermocouple, the culture
temperature was measured. An ampliŽ er was placed
between the A=D converter and thermocouple to convert
the 0–4 mV pulses obtained from the thermocouple to 0–10
volt pulses. For both Internal Model Control and Self-
Tuning PID controller related control algorithms were
developed for on-line control purposes. Heat given from
the immersed heater was chosen as the manipulated vari-
able. The value of the manipulated variable was computed
with the control algorithm. This value was converted into a
signal and then it was passed through a D=A converter and
converted into 0–4 mV pulses before they reached the triac
module (see Figure 1).
In the experimental work, a computer controlled system
was used to observe and control the culture temperature.
The experimental procedure is summarized below.
Initially, the bioreactor was Ž lled with the culture medium
consisting of glucose and mineral salts. The medium was
heated to the desired temperature of 30° C. The experimental
operating conditions are shown in Table 1. Finally, the
medium was inoculated to start the cell growth. During
Figure 1. Experimental system. (1) oxygen meter; (2) pH meter; (3)
preampliŽ er; (4) thermocouples; (5) computer; (6) agitator; (7) rotameter;
(8) microbiological Ž lter; (9) immersed heater; (10) triac; (11) pump; (12)
air; (13) condenser; (14) cooling water reservoir.
244 BURSALI et al.

Table 1. Optimal operating conditions used in experimental · calculate the predicted controlled variable, i.e. the output
studies and simulations. from the model Gm (s): The dynamic model can be
Temperature 30° C simulated in the discrete form as:
pH 4
Mixing rate 300 rpm ym (k) = Km (1 - e- t=tm )u(k - N - 1) + e- t=tm y(k - 1)
Culture medium volume 1.6 l
Cooling water  ow rate 1.4 ml s- 1 (8)
Qo 1.7 cal s- 1
Air  ow rate 0.83 vvm where t is the sampling time;
· calculate the difference between the measured and model-
predicted controlled variables, then Ž nd the error signal
as:
the cell growth, the increase of the culture temperature and
cell concentration were observed. Controlled and uncon- e(k) = ys (k) - [ y(k) - ym (k)] (9)
trolled conditions were realized experimentally. Reaction
heat was assumed as a load effect. · calculate the IMC controller output as:

INTERNAL MODEL CONTROL u(k) = (1 - e- t=tf )e(k - 1)

The IMC uses a model of the process open-loop Gm (s)
transfer function. The Ž rst order dynamic model with dead
time was assumed in this study. The IMC system with a
single Ž lter is:
K m e - dm s
Gm (s) =
tm s + 1
This model is factored into the product of the two factors to
give:
Gm (s) = G+m (s) Gm- (s)
Here Gm+ (s) is the non-invertible part, and Gm- (s) is the
invertible part, and has an inverse that is causal and stable,
leading to a realizable stable controller:
Km
Gm- (s) = and Gm+ (s) = e- dm s
tm s + 1
The IMC controller eliminates all elements in the process
model Gm(s) that lead to an unrealizable controller by taking
the inverse of only the invertible factor to give:
Gc (s) = [G-m (s)]- 1 f1
A Ž lter ( f1) of the feedback signal is placed before the
controller to modulate the manipulated variable behaviour
and to increase the robustness of the system, so a good
control performance can be achieved. The IMC Ž lter f1 is
given as:
+ (e- t=tm e- t=tf - e- t=tm )e(k - 2)
+ Km (1 - e- t=tm )e- t=tf u(k - 1) (10)
(1) SELF-TUNING CONTROL
A self-tuning PID controller acts simply as a well-tuned
PID controller12. This means that it should be possible to
apply the self-tuner to the same processes as the conven-
(2) tional PID controller and that a pole-placement based
STPID algorithm is likely to produce a robust, low order
controller.
The process model used is a CARMA (Controlled Auto
Regressive Moving Average) model13–14. The equation for a
single-input single output system to be controlled is:
(3)
A(z- 1 )y(t) = z- k B(z- 1 )u(t) + C(z- 1 )e(t) (11)
Where A, B and C are polynomials in the backward shift
operator (z- 1), and k is the system time delay. A and B
represent the poles and zeros respectively of the discrete
(4) time system associated with the control input. C contains the
zeros of process noise, and e(t) is an uncorrected random
sequence. y(t) is system output at time t and u(t) is system
input. This model can be re-expressed as:
y(t) = XT (t) y(t) + e(t) (12)

1 Where X is the data vector, y is parameter vector deŽ ned as

f1 = (5)
(tf s + 1)r the collection of coefŽ cients in the A, B and C polynomials.
y and X are given by:
Here tf is the desired closed-loop time constant, and r is a
positive integer. One of the Ž lter forms for plant=model y(t) = [a1 ; a2 ; . . . ; ana ; b0 ; b1 ; . . . ; bnb ; d0 ; c1 ; c2 ; . . . ; cnc ]
mismatch is: (13)
1 - aF
f (z) = (6)
1 + a F z- 1
XT (t) = [ y(t - 1); . . . ; y(t - na); u(t - 1); . . . ;
-t
Where aF = e =tf ; tf is the time Ž lter constant. The u(t - nb - 1); 1; e(t - 1); . . . ; e(t - nc)] (14)
controller output can be calculated employing the invertible
part as: The discrete form of the PID control algorithm can be
t s+ 1 1 converted into a self-tuning equivalent control equation as
Gc = [Gm- (s)]- 1 f1 = m (7) follows:
K m tf s + 1
The IMC system algorithm is summarized as: u(t) = (S=R)[r(t) - y(t)] (15)

Trans IChemE, Vol 79, Part C, December 2001

 EFFECT OF TUNING PARAMETERS ON MODEL CONTROL METHODS 245

Here r(t) represents the set point, and: By equating the denominator of equation (24) with
-1 -2
equation (25), the following relationships are obtained:
S = s0 + s1 z + s2 z (16)
t1 - a1 + 1
s0 =
Dt tD b0
s0 = K C 1 + + (17) t2 - a2 + a1
2tI Dt s1 = (26)
b0
t3 + a2
Dt 2tD s2 =
s1 = K c - 1 + - (18) b0
2tI Dt
The discrete form of the necessary incremental PID control
tD -1 law15 may be written in terms of the change in the control
s2 = K C and R = (1 - z ) (19) signal as:
Dt
Here Dt is the sampling interval. The PID constants can be DU = s0 e(t) + s1 e(t - 1) + s2 e(t - 2) (27)
found from the values of s1, s2 and s3. Substituting the
control equation into CARMA, the process model yields the The steps in the operation of the self-tuning used in this
following closed-loop response equation: study can be given as:
(1) apply a perturbation to the system as a forcing function
z- 1 BS RC and attain the plant output;
y(t) = r(t) + e(t) (20)
AR + z- 1 BS AR + z- 1 BS (2) estimate A and B from the CARMA model using Bier-
man UDUT update algorithm;
The characteristic equation is called a Tailoring poly-
(3) calculate s0, s1 and s2 from the equations;
nomial T and it is given by:
(4) Ž nd Kc, tI and tD from the equations;
T (z- 1 ) = A(z- 1 )R + z- 1 B(z- 1 )S(z- 1 ) (21) (5) obtain the incremental control signal from equation
(27);
The properties of this closed-loop can be varied by placing (6) output the updated control signal to the process;
the poles of the characteristic equation within the unit-circle (7) return to 1.
in the z plane. The coefŽ cients of the A and B polynomials
In this work, the form of the system model to be
are estimated from the Bierman UDUT algorithm9, and the
controlled is preserved to ensure that only one set of PID
coefŽ cients of the T polynomial are deŽ ned by the user. s0,
controller coefŽ cients is produced from the design and the
s1, s2 can be found by solving the set of simultaneous
integral action in the PID controller provides steady-state
equations obtained from the closed-loop equation.
even if the parameter values of the system or controller
The degrees of the polynomials in the characteristic
change.
equation are:
na + nr = nb + ns + 1 = nt (22)
RESULTS
Where ns is the degrees of the S and it is taken as 2, and nr is Some theoretical and experimental studies have been
the degree of R polynomials, the value must be 1 because of carried out to observe the performance of IMC and
the polynomial representation of velocity form of the PID STPID control systems to track the reactor temperature at
algorithm. This means that na = nb + 2 and nt = nb + 3 = the desired set point. In the dynamic work, the culture
na + 1: If a second order A polynomial (na = 2; nb = 0 and temperature was not controlled and the inhibitory effect of
nt = 3) is selected, a unique set of PID controller coefŽ - the increasing culture temperature on the speciŽ c growth
cients can be obtained from the design. If the order of the A rate of cells was observed. Hence the necessity of control-
polynomial is three, i.e. na = 3; nb = 1 and nt = 4; all the ling the culture temperature was realized.
coefŽ cients of T polynomial should be user deŽ ned to place In the Ž rst part of the study, the theoretical simulation
the poles of the characteristic equation easily. In this case, work was carried out to calculate the efŽ ciency of the related
the system transfer function chosen is a third order T control systems. This simulation program consists of mate-
polynomial (na = 2; nb = 1) and has the form: rial and energy balance developed for this batch bioreactor.
b0 z- 1 Necessary equations for the energy and material balance
y(t) = u(t) (23) were taken from literature16. Dynamic behaviour of the
1 + a 1 z- 1 + a 2 z- 2 system under various load effects were investigated by
The closed loop relationship is obtained by combining the using this simulation program. Parameters of parametric
system model equation (23) and the controller equation (15) models were also calculated with the data obtained from
as: this simulation program.

b0 z- 1 S
y(t) = r(t) (24) Table 2. Comparison of speciŽ c growth rate at controlled and uncontrolled
R(1 + a1 z- 1 + a 2 z- 2 ) + b 0 z- 1 S temperature.

The equivalent closed loop T polynomial is of the form: Controlled temperature Uncontrolled temperature
- 1
m (h ) 0.57 0.23
T = 1 + t1 z- 1 + t2 z- 2 + t3 z- 3 (25)

Trans IChemE, Vol 79, Part C, December 2001

246 BURSALI et al.
A comparison of the speciŽ c growth rate between
controlled and uncontrolled cases was given in Table 2.
Temperature control is very effective in keeping the yeast
concentration at the desired value. Very little  uctuation at
the desired temperature value results in high difference in
the yeast concentration. The increase of the culture tempera-
ture and cell concentration during the cell growth are shown
in Figures 2 and 3. It can be seen that maximum cell
concentration was obtained at the end of the exponential
growth phase, 4.5 h. For this reason, a comparison of the
two different controller performances was realized between
0 and 4.5 h time interval. In the second part of the work, the
experimental study was realized to observe the dynamic
behaviour of the batch reactor, and parameters of the
nonparametric model were determined. Reaction media
was placed into the bioreactor for this purpose. The reactor
was heated by means of an immersed heater, then cooling
water was passed through the reactor cooling jacket. In this
case, the heat given by the heater was absorbed by the
cooling water and, this reactor Ž lled with reaction media,
was considered as a heat exchanger. This system can reach a
steady state condition with deŽ ned values of heat input and
cooling  ow rate (see Table 1). Therefore, IMC and STPID
systems can be designed for processes operating in the
vicinity of a steady state. An experimental reaction curve
35
34
33
Temperature ( C)
o
32
31
30
29
28
0 1 2 3 4 5 6 7
Time (h)
Figure 2. The increase of growth medium temperature with time.
8 42
Yeast concentration (g/L)
6
4
2 32
desired theoretically
uncontrolled experimental
0 28
0 1 2 3 4 5 6 7
Time (h)
Figure 3. Theoretically desired and uncontrolled yeast concentration
proŽ les carried out under optimal conditions.
was found by performing the open-loop step test. When the
system is at the steady state conditions as given in Table 1, a
step change is given to the heat input (DQ = 21.7 cal s- 1).
The time variation of temperature to this effect is presented
in Figure 4. The representation of the transfer function of the
reactor in equation (1) was obtained from this Ž gure. Heat
input from the immersed heater was selected as a manipu-
lated variable.
For the IMC system, the nonparametric Ž rst order dead
time model presented in equation (1) was obtained to
represent the dynamic behaviour of the reactor, which is
given as follows:
0:56e- 3:5s
Gp = (28)
37:5s + 1
For this transfer function of the system, the unit of the
time constant and dead time are minute. Sample time t was
taken as 37.5 sec. The inverse of the Laplace transform for
this transfer function was evaluated and then time variation
of the reactor temperature was given, as shown in Figure 4.
In addition, the simulation program, having only the energy
balance of the batch reactor, was used to represent the
dynamic behaviour of the system to obtain the theoretical
open loop step test. A similar step change was given to the
system when the reactor was in a steady state condition as
given in Table 1. The time response of the theoretical reactor
temperature is calculated and given in Figure 4. As can be
easily observed from Figure 4, the agreement among the
responses of the reactor temperature obtained from the
computer simulation program, experimental data and inverse
of the transfer function for the batch bioreactor is sufŽ -
ciently good.
The simulation program with energy balance is used to
calculate the parameters of the parametric CARMA model
for STPID control. Theoretical estimation algorithm is given
as follows. When the batch bioreactor is in the steady state
condition given in Table 1, the Pseudo Random Binary
Sequence (PRBS) signal is given to the heat input to disturb
8 the system. The Bierman algorithm is used to calculate the
CARMA model parameters with input output data. The
magnitude of the PRBS and rate of sampling were chosen
by knowledge of the process dynamics and the behaviour of
the Ž nal control elements. A second order polynomial is
40
38
Temperature ( C)
o
36
34
experimental
theoretical
Laplace
30
CARMA
8 0 10 20 30 40 50 60 70 80
Time (min)
Figure 4. Process reaction curve.
Trans IChemE, Vol 79, Part C, December 2001
 EFFECT OF TUNING PARAMETERS ON MODEL CONTROL METHODS 247

sufŽ cient to represent the denominator plant dynamics.
From estimation procedure, the coefŽ cients found are:
0:00876
y(t) = u(t - 1) (29)
1 - 0:5387z- 1 - 0:4603z- 2
The time response of the CARMA model with heat input
change (Du = 21.7 cal s- 1) is given in Figure 4. SufŽ cient
agreement is obtained. It can be concluded that the esti-
mated CARMA model can be used to design the STPID
control.
Both system transfer function and CARMA model para-
meters are not changed during the fermentation processes.
These approaches are sufŽ ciently acceptable for this study.
Only the tuning parameters for both control systems were
changed to obtain sufŽ cient control performance by elim-
inating the model error from real system.
In the third part of the study, the theoretical simulation
work was carried out prior to experiment. The total simula-
tion program using material and energy balance, were used
to calculate the time response of the batch bioreactor with
IMC and STPID control systems. The best values of control
tuning parameters were determined using this simulation
program. As a means of comparing the performance of the
IMC and the STPID controllers, the integral square of the
error (ISE) is computed for the closed loop process output,
where:
tf
ISE = [ y(t) - r(t)]2 (30)
t= 0
set point. Tuning control parameter tf is varied to obtain the
desired and efŽ cient control performance in IMC system. So
the response of the IMC system to a change in the set point
is examined with different Ž lter time constants and the
related theoretical results are given in Figure 5. As can be
seen from Figure 5, when larger tf values are used, system
response shows sluggish behaviour, smaller values give fast
and smooth response.
The theoretical temperature response of the STPID
system to a similar step change in the set point were
calculated (see Figure 6). The tuning control parameter t1
of T polynomial is varied to obtain sufŽ cient control
performance. Three different t1 values were tested and
system responses examined. It was seen that when the t1
value is placed near the edge of the unit circle, the response
is unstable, as expected. A comparison of the performance
of the controller for the set point change based on ISE
values are given in Table 3. In addition, the ISE values of
IMC control system gives the best performance according to
ISE values, so nonparametric model based control gives
more satisfactory result than parametric model based
control.
In another part of the study, step change in the cooling
water  ow rate is chosen as a load effect and the properties
of IMC and STPID control systems have been tested for
33

There are three parameters in the IMC algorithm that have

Temperature ( C)

32
to be deŽ ned by the user viz, NP, NC and tf. NP and NC can
o

be chosen by observing the dynamic behaviour of the tf =0.1

system with step change and computational effort. In this 31 t =10
f
work, NP = 4 and NC = 1 were taken. Filter time constant, first set point
tf, was selected as the tuning parameter to remove the model second set point
error coming from the estimated model parameters. In all 30
theoretical and experimental study, tf is varied to obtain the
desired control performance by calculating performance 29
criteria. 0 1 2 3 4 5 6 7 8
In STPID control, the values of the controller parameters Time (h)
were obtained from the tailoring polynomial T which
changes the properties of the controller by pole locations.
As in common practice, t1 is employed as a tuning para- Figure 5. Response of IMC system with varying Ž lter time constant to a
meter, while t2 and t3 are taken as zero. Similarly as in IMC change in set point.
system, tf is varied to obtain the desired control perfor-
mance in theoretical and experimental study. 33
The PID control of the batch reactor was utilized to
compare the efŽ ciency of two control systems. Necessary 32
data for PID control system is taken from relevant litera-
Temperature ( C)

t1= -0.1
ture17. PID control parameters were adjusted; Kc = 60:25;
o

t1= -0.6
tI = 1.219 min and tD = 0.18 min. By using Cohen Coon 31 t = -0.9
1
method under all conditions, the performance of the error first set point
(ISE) is computed for the closed loop process output. second set point

In theoretical control work, two types of condition were 30

used to test the performance of the IMC and STPID control
systems by changing the tuning parameters. In this part of
29
the study, the response of the theoretical system with two 0 1 2 3 4 5 6 7 8
different control systems to set point change were investi-
gated. Comparison between the performance of the IMC and Time (h)
STPID systems was made on the basis of subsequent ISE
values for the closed-loop response method. To make a good Figure 6. Response of STPID system with varying t1 values to a change in
comparison a step change from 30° C to 32° C was given to set point.

Trans IChemE, Vol 79, Part C, December 2001

 248 BURSALI et al.

Table 3. Subsequent closed-loop ISE values for set point change.

IMC STPID PID

Parameter tf = 0:1 tf = 10 t1 = 7 0.1 t1 = 7 0.6 t1 = 7 0.9 KC = 60:25 tI = 1:219 tD = 0:18
ISE 3.47 3.31 4.67 4.74 5.09 5.5

disturbance rejection. Simulation programming is used to
calculate the system output.
For the IMC control system, when the system is in steady-
state condition as given in Table 1, a step change from
1.4 m s- 1 to 0.7 m s- 1 is given to the cooling water  ow rate
and time response of the system is examined using simula-
tion program. Relevant results are given in Figure 7. Again
two Ž lter time constants are chosen for examining the
controller performance. Similar calculations are made for
tuning the Ž lter time constant. Small tf value gives fast and
smooth responses, greater values shows sluggish and oscil-
33
t = 0.1
f
t = 10
f
Temperature ( oC)
latory behaviour. System response under STPID control for
load effect is shown in Figure 8. Three different t1 values are
again chosen to test the performance of the relevant control
system. The ISE values are computed for both control
systems and the results are shown in Table 4. The IMC
performance is marginally better than the STPID perfor-
mance. However, both of these control strategies are much
better than conventional PID control results in the same
table.
Experimental work was carried out in light of the theore-
tical studies. The tuning parameters which give the best ISE
values were used. Necessary experimental conditions are
given in Table 1. The experimental results of temperature
control by IMC algorithm are given in Figure 9. As can be
seen, even if the culture temperature is at the set point at the
beginning of the experiment, the IMC system brings this
temperature quickly to the desired value and then it follows

32
set point
set point smoothly. Second control was made with STPID
control algorithm and the relevant results are shown in
31 Figure 10. Initially the culture temperature was again at
the set point, but the response was more sluggish and
oscillatory than the IMC algorithm. The ISE values, both
30 experimental and theoretical, were computed for each
control system and are shown in Table 5. Table 5 and
Figures 9 and 10, indicate that the performance of the
29
0 1 2 3 4 5 6 7 IMC system gives better and more efŽ cient response in
Time (h) following the desired set point than the performance of other
algorithms.
Figure 7. Response of IMC system to disturbance rejection with varying
Ž lter time constants (m1 = 1.4 mls- 1, m2 = 0.7 mls- 1).
DISCUSSION
35 In this study, the performance and quality of the IMC and
t1= -0.1 STPID controllers have been examined using ISE criterion.
34 t1= -0.6 Experimental and theoretical work have been undertaken to
Temperature ( o C)

t1= -0.9
set point
observe the performance of these control systems in the face
33 of load disturbance and set point change. Heat input to the
bioreactor was chosen as the manipulated variable, and the
32
primary control objective is to maintain the bioreactor
31
temperature at the desired value. In all cases, the manipu-
lated variable which is heat input produced good sensitivity
30 and rapid response. In the experimental work, when the
process is under the reaction heat effect, IMC shows better
29 performance than the STPID controller with little ISE
0 1 2 3 4 5 6 7 values, and gives more efŽ cient control than STPID. Similar
results were also observed in theoretical work. In all
Time (h)
theoretical and experimental studies, the PID control
Figure 8. Response of the STPID system to load rejection with varying t1 system did not show desired control performance depending
values (m1 = 1.4 mls- 1, m2 = 0.7 mls- 1). on ISE criteria.

Table 4. Subsequent closed-loop ISE values for closed-loop response method under load effect.

IMC STPID PID

Parameter tf = 0:1 tf = 10 t1 = 7 0.1 t1 = 7 0.6 t1 = 7 0.9 KC = 60:25 tI = 1:219 tD = 0:18
ISE 1.27 3.98 1.32 6.07 59.21 91.3

Trans IChemE, Vol 79, Part C, December 2001

 EFFECT OF TUNING PARAMETERS ON MODEL CONTROL METHODS 249

33 STPID Self-Tuning PID control

experimental T reactor temperature, ° C
theoretical Qo steady state heat input, cal s- 1

32 set point Q heat input, cal s- 1

Temperature ( C)

U(z) manipulated variable

o

y process output
ysp output set point
31
Greek letters
tD derivative time constant, minutes
30 tf Ž lter time constant
tI integral time constant, minutes
tm model time constant
Dt sampling time, minutes
29 m speciŽ c growth rate, h- 1
0 1 2 3 4 5 6 7 8
Time (h)
REFERENCES
Figure 9. Experimental temperature control (IMC) in the face of reaction 1. Bailey, J. E. and Ollis, D. F., 1986, Biochemical Engineering Funda-
heat, tf = 0.1. mentals, 2nd ed. (Mc Graw-Hill, Singapore), pp 689–725.
2. Cardello, R. J. and San, K. Y., 1988, The design of controllers for batch
bioreactors, Biotechnol Bioeng, 32: 519.
33 3. San, K. Y. and Stephanopoulus, G., 1984, Studies on on-line bioreactor
identiŽ cation. IV utilization of pH measurement for product estimation,
experimental
theoretical
Biotechnol Bioeng, 26: 1208.
32 4. Douglas, A. and Ramirez, W. F., 1988, Optimal temperature control for
Temperature ( C)

set point
batch beer fermentation, Biotechnol Bioeng, 31: 224.
o

5. Suzuki, T., Yamane, T. and Shimizu, S., 1986, Control of carbon source
supply and dissolved oxygen by use of carbon dioxide concentration of
31 exhaust gas in fed-batch culture, J Ferment Technol, 64(4): 317.
6. KahveciogÏ lu, A., Ertunç, S., Akay, B., HapogÏ lu, H. and Alpbaz, M.,
2000, Adaptive Control of S.cerevisiae Production, Research 2000
30 (Institution of Chemical Engineers, UK), pp 38.
7. ErdogÏ an, S., Özkan, G. and Alpbaz, M., 1998, Self-tuning control of
batch polymerization reactor, J Chem Eng Japan, 31(4): 499–505.
29 8. Yüce, S., Hasaltun, A., ErdogÏ an, S. and Alpbaz, M., 1999, Temperature
0 1 2 3 4 5 6 7 8 control of a batch polymerization reactor, Trans IChemE, Part A, Chem
Eng Res Des, 77(A5): 413–420.
Time (h) 9. Bierman, G. J., 1976, Measurement updating using the U-D factoriza-
tion, Automatica, 12: 375.
Figure 10. Experimental temperature control (STPID) in the face of reaction 10. Levenberg, K., 1994, A method for the solution of certain non-linear
heat, tf = 7 0.1. problems in least squares, Quarterly Appl Math, 2: 164–168.
11. Wang, P., Kwok, D. P., 1994, Optimal design of PID process controllers
based on genetic algorithms, Cont Eng Prac, 2(4): 641–648.
Table 5. ISE values for closed loop response method. 12. Wittenmark, B. and Aström, K. J., 1984, Practical issues in the
implementation of self-tuning control, Automatica, 20(5): 595.
ISE ´ 100 13. Seborg, D. E., Edgar, T. F. and Shah, S. L., 1986, Adaptive control
strategies for process control: a survey, AIChe J, 32(6): 881–909.
Experimental Theoretical 14. Newell, R. B. and Lee, P. L., 1987, Applied Process Control (Prentice
Hall, USA), pp 75–79.
IMC (tf = 1) 1.35 24 15. Stephanopoulos, G., 1984, Chemical Process Control: An Introduction
STPID (t1 = 7 0.1) 11.52 24 to Theory and Practice (Prentice-Hall, Inc., USA), pp 310–315.
PID 18.22 25.48 16. Bursali, N., 1997, Application of Optimal Adaptive Generalized
Predictive Control Method to a Batch Bioreactor, Ph.D. Thesis
(Ankara University, Turkey).
17. KahveciogÏ lu, A., Application of Self Tuning PID Control to a Biore-
NOMENCLATURE actor in which S. cerevisae is Produced and Determination of Optimal
Control Parameters, Master Thesis (Ankara University, Turkey).
A=D Analog=Digital converter
d(z) disturbance
d(z) feed-back signal
dm dead-time, minutes ACKNOWLEDGEMENT
e(z) IMC controller input
The authors gratefully acknowledge Ankara University Research Fund
F(z) Ž lter transfer function
for providing Ž nancial support.
GC(z) Internal Model Controller transfer function
GP(z) real process transfer function
Gm(z) process model transfer function
IMC Internal Model Control ADDRESS
ISE Integral Square Error
KC controller gain Correspondence concerning this paper should be addressed to Pro-
Km model gain fessor M. Alpbaz, Department of Chemical Engineering, Engineering
na degree of A polynomial Faculty, Ankara University, TandogÏ an, Ankara, 06100 Turkey. E-mail:
nb degree of B polynomial alpbaz@science.ankara.edu.tr
nr degree of R polynomial
nS degree of S polynomial The manuscript was received 24 July 2000 and accepted for publication
nt degree of T polynomial after revision 16 August 2001.

Trans IChemE, Vol 79, Part C, December 2001