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# Institution of Chemical Engineers
www.ingentaselect.com=titles=09603085.htm Trans IChemE, Vol 81, Part C, December 2003
T
he control of optimum growth medium temperature of a batch bioreactor in which
S.cerevisiae was grown under aerobic conditions has been studied. The generalized
minimum variance (GMV) algorithm was applied for on-line computer control. A
controlled autoregressive moving average model relating the bioreactor temperature and heat
input was used to show the dynamic behaviour of the system. The heat input to the bioreactor
was chosen as a manipulated variable. A pseudo-random binary sequence signal was applied to
the system and the model parameters were determined using the Bierman algorithm. More
suitable values of the GMV controller parameters were determined using a total simulation
program. These control parameters were used in experimental and theoretical work under
several disturbances.
327
328 ERTUNÇ et al.
bioreactor temperature. Heat input was chosen as a manipu- Yeast growth rate for exponential growth phase is given by
lated variable. A total simulation program was used to
dX
obtain the related CARMA model and control parameters. ˆ mX (3)
Firstly CARMA model parameters were determined by dt
using the Bierman algorithm (Biermann, 1976) and then A functional relationship between the speci c growth rate
using these parameters a CARMA model was applied to (m) and an essential compound’s concentration was proposed
achieve suf cient GMV control performance. Secondly by Monod (Clarke and Gawtthrop, 1979).
some control parameters were tested theoretically to deter-
mmax S
mine the best values of them; using these parameters the mˆ (4)
GMV control system was examined theoretically. In the KS ‡ S
third part of the work, the calculated optimal control and The Monod equation in its original form is not well suited
model parameters were used to realize GMV control experi- for estimation of the parameters mmax and KS. Therefore, by
mentally. Very satisfactory control results were achieved. rearranging equation (4) the following options can be
derived for data plotting and graphical parameter evaluation:
MATHEMATICAL MODEL OF THE BIOREACTOR 1 K 1 1
ˆ S ‡ (5)
In this study the following stoichiometric illustrations m mmax S mmax
were considered to occur in the batch culture. plotting equation (5) as 1=m vs 1=S is known as Lineweaver–
Burke plot.
(1) Yeast growth:
The stationary phase starts at the end of exponential phase
aC6 H12O6 ‡ bO2 ‡ c(NH4 )2 SO4 dX
ˆ0 (6)
! d(cells) ‡ eH2 O ‡ f CO2 ‡ DHC dt
The death phase follows the stationary phase and the rate of
(2) Glucose catabolism via oxidative pathway: death is described with rst-order kinetics:
dX
C6 H12 O6 ‡ 6O2 ! 6CO2 ‡ 6H2 O ˆ ¡kd X (7)
dt
¡1
¡DHS ˆ 673 kcal mol substrate The parameters of these kinetic models were de ned by
means of the related experimental curve and a computer data
Some assumptions were made in the mathematical model- bank. A plot of ln X vs t yields a line of slope ¡kd (Shuler
ling of the cooling jacketed batch bioreactor. These are: and Kargi, 1992). The least square method was used to
° the bioreactor was assumed to be a well-mixed one with calculate the kinetic parameters.
The rate of oxygen uptake is denoted as OUR (oxygen
temperature and cell concentration not varying with
uptake rate):
position in the bioreactor;
° the mean speci c heat capacity of the system contents is mX
OUR ˆ (8)
independent of the composition and temperature changes; Y X= O2
° the inlet temperature of the cooling water was assumed to DX
be constant; YX=O2 ˆ ¡ (9)
DO2
° the decrease in volume due to increase in density was
neglected, therefore the changes of biomass concentration The global dissolved oxygen material balance in the growth
were accepted as being equal to changes occurring during medium in the presence of oxygen-consuming cells is
written as follows (Cardello and San, 1988):
the exponential growing phase;
° it was assumed that the change of viscosity had no effect d(DO) mX
ˆ kL a[(He1 CO ) ¡ DO] ¡ (10)
upon the reaction kinetics; dt YX = O 2
° the speci c heat of the vessel is relatively smaller than
Exit oxygen material balance in gas phase is:
that of the reaction mixture; it is therefore omitted and µ
does not affect any discrepancies between the model and dCO RT
the experimental results. ˆ i ¡ kL a[(He1 CO ) ¡ DO]
dt epM1
¶
Material balances on yeast growth under aerobic condi- P M F(Yin ¡ CO )
tions are given below. ‡ i 1 (11)
RTVL
Model for glucose consumption
Yield factor based on CO2 is:
dS mX
ˆ¡ (1) DX
dt YX=S YX=CO2 ˆ (12)
DCO2
where YX=S yield factor is given by: Dissolved CO2 material balance in growth medium:
DX d(DCO2 ) mX
YX=S ˆ ¡ (2) ˆ ¡ (KL a)c (DCO 2 ¡ He2 CCO2 ) (13)
DS dt YX=CO2
J ˆ E{f2t‡k } (23)
P ˆ 1, Q ˆ l, Rˆ1
C B
yt‡k ˆ e ‡ u (24)
A t‡k A t‡k
PB ‡ QA PC
ft‡k ˆ ut ‡ e ¡ Rrt (25)
Figure 1. Heat balance on microbial utilization of substrate. A A t‡k
This expression for ft‡k is effectively the addition of two MgSO4 ¢ 7H2O, 0.0017% CaCl2 ¢ 4H2O and 2% agar. The
independent terms. The rst term can be de ned as: cells growing on the newly prepared slants were inoculated
1 into the same liquid medium (without agar) and cultivated at
ft‡k jt ˆ [(BE ‡ QC)ut ‡ Gyt ¡ CRrt ‡ Ed] (26) 32¯ C for 24 h. Cells in the exponential growth phase were
C inoculated from the seed culture into the growth medium
and represents the best forecast of ft‡k established on data which contained 2% glucose, 0.6% yeast extract, 0.3%
up to time t. The second term is: K2HPO4, 0.335% (NH4)2SO4, 0.376% NaH2PO4, 0.052%
MgSO4 ¢ 7H2O, 0.0017% CaCl2 ¢ 4H2O and 0.2 ml antifoam A.
Eet‡k ˆ ft‡k ‡ f^ t‡k jt (27) Inoculum, 1:10, was used for the experiments. Glucose,
which is the output prediction error originating from the which was used as a carbon and energy source, and salt
noise sources et‡1 , et‡2 , . . . , et‡k . It was pointed out pre- solutions were separately sterilized in an autoclave for
viously that these latter sources cannot be removed by the 20 min at 121¯ C. The bioreactor and other ancillary equip-
control signal ut. ment were sterilized with 70% ethanol at pH 2. Air was
Clearly J is minimized by setting the predicted output supplied continuously to the bioreactor by a sparger after
equal to zero, i.e. passing it through an air rotometer and microbiological
lter. Experiments were carried out at 600 rpm agitation
ft‡kjt ˆ 0 (28) rate. Cell concentration was determined turbidimetrically at
This gives the control law: 580 nm with a Shimadzu (Tokyo, Japan) model UV-160A
spectrophotometer. At every sampling time the temperature
Fut ‡ Gyt ¡ Hr t ‡ Ed ˆ 0 (29) of the growth medium was measured by a thermocouple.
where The value of the manipulated variable, which is the heat
given from the immersed heater, was computed according
F ˆ BE ‡ QC, H ˆ CR (30) to the controller algorithm settled on on-line computer
Hence: and adjusted by a triac module. A schematic of the on-line
control system and experimental system is given in Figure 3.
Hrt ¡ Gyt ¡ Ed
ut ˆ (31)
F
The steps in the implementation of the GMV algorithm may
be summarized as: RESULTS AND DISCUSSION
(1) Apply a PRBS to the system as a forcing function and The application of a GMV control system to the growth
medium temperature of the bioreactor in which S. cerevisiae
obtain the plant output.
was grown in aerobic conditions was realized. Theoretical
(2) Estimate F, G, H from equation (29), implementing the and experimental control studies were carried out to observe
Bierman U–D update algorithm. the ef ciency of the control system.
(3) Employ equation (31) to evaluate the control signal. The following experimental procedure was performed to
(4) Apply the control signal. determine the effectiveness of the GMV control system and
(5) Return to step (1). to calculate the control and system model parameters.
For this purpose, growth medium was lled into the jacketed
bioreactor. When the bioreactor was heated by means of an
EXPERIMENTAL SYSTEM
immersed heater, cooling water was passed throughout the
The yeast S. cerevisiae NRRL Y-567, which was obtained reactor cooling jacket. In this case, the bioreactor can be
from the ARS culture collection (Northern Regional considered as a heat exchanger. Thus the heat given out by
Research Center, Peoira, IL, USA), was used in the present the heater was absorbed by the cooling water. If this is taken
study. The stock cultures were maintained on agar slants into consideration the bioreactor can be considered to be
containing 2% glucose, 0.6% yeast extract, 0.3% K2HPO4, continuous as regards energy. When such a bioreactor is
0.335% (NH4)2SO4, 0.376% NaH2PO4, 0.052% used with de ned values of heat input and cooling ow rate,
the system can reach the steady-state condition shown in conditions. A two-level factorial experimental design was
Table 1. In all the identi cation work, this steady-state used to identify a related model. Box–Wilson’s steepest-
operating condition was utilized. The mathematical model ascent method was applied to nd the optimal operating
equations of this reactor [equations (18)–(20)] were solved conditions using an identi ed statistical model (Box and
using the fourth-order Runge–Kutta integration method. Wilson, 1951). Four independent variables which have an
This simulation algorithm with initial steady-state condition effect on aerobic yeast production were selected. Tempera-
shown in Table 1 was used to calculate the system CARMA ture, pH, air ow rate and agitation rate were the indepen-
model and control parameters. The design philosophy of dent variables. Yeast productivity was selected as the
the GMV control system basically depends on this approxi- dependent variable. A rst-order statistical model was
mation. In addition, the heat released during the reaction chosen to illustrate the dependence of the yeast productivity
was accepted as a disturbance for this system. For control on the operating parameters. Optimum pH, temperature, air
application, heat input from the immersed heater was chosen ow rate and agitation rate were determined as 5, 32¯ C,
as a manipulated variable. 1 vvm and 600 rpm, respectively (Alpbaz et al., 1997). All
Optimal operating conditions were calculated by identify- the optimal operating conditions are shown in Table 2.
ing a static model for S. cerevisiae production under aerobic Theoretical desired and uncontrolled experimental yeast
Figure 4. Desired theoretical and experimental uncontrolled yeast concen- Figure 6. Theoretical and experimental results for the bioreactor tempera-
tration pro les carried out under optimum conditions. ture when GMV control is applied (l ˆ 0.000135).
Figure 7. Yeast concentration pro le for GMV control. Figure 9. Yeast concentration pro le for GMV control under a positive step
change given to the cooling ow rate at time 0 minute (m1 ˆ 46 ml=min,
m2 ˆ 60 ml=min).
Figure 8. Theoretical and experimental results for the bioreactor tempera- Figure 11. Yeast concentration pro le for GMV control work under a
ture using GMV control under a positive step change given to the cooling negative step change given to the cooling ow rate at time 0 minute
ow rate at time 0 minute (m1 ˆ 46 ml=min, m2 ˆ 60 ml=min). (m1 ˆ 46 ml=min, m2 ˆ 31.5 ml=min).
CONCLUSION t time, h
T bioreactor operating temperature, ¯ C
In all control work, the identi cation method used in this Tc mean temperature of cooling water, ¯ C
research is very successful and applicable to design the Tci inlet temperature of cooling water, ¯ C
Tco outlet temperature of cooling water, ¯ C
GMV control system. GMV control system based on the U overall heat transfer coef cient, J m¡2 s¡1 ¯ C¡1
standard CARMA model is very successful in forcing u(t), ut input variable at time t
the bioreactor temperature to follow the optimum set point Vc volume of cooling water, cm3
with little oscillation and without offset. VL volume of growth medium, cm3
In all the control work, the desired conversion was Yin inlet air oxygen mole fraction
y(t), yt output variable at time t
obtained satisfactorily. The desired yeast concentration X microorganism (yeast) concentration, g cell l¡1
was shown in Figure 4. Very small deviations from optimal YX=S substrate yield coef cient, g cell g substrate¡1
set point of 32¯ C during temperature control cause consider- YX=O2 oxygen yield coef cient, g cell g O2¡1
able difference in the desired yeast concentration. In the 1=YH metabolic heat evolved per gram of cell mass produced,
J g cell¡1
previously published work (Karagoz et al., 2000), the same z, z¡1 forward and backward shift operators
control strategy was applied to a polystyrene polymerization
reactor to keep the reactor temperature on a predetermined Greek symbols
trajectory. It can be seen that this control strategy is e fraction of the reactor that is occupied by a gas phase
applicable to various batch processes with different orders m speci c growth rate, h¡1
and dead-times. mmax maximum growth rate, h¡1
r growth medium density, g cm¡3
Various control strategies were applied to the same rc cooling water density, g cm¡3
bioreactor for growth medium temperature of baker’s yeast DHs heat of combustion of the substrate, j mol substrate¡1
production in previously published work (Bursali et al., DHc heat of combustion of cells, j g cell¡1
2001; Akay et al., 2002; Bursali et al., 2001). The speci c l control weighting
growth rate m (h¡1) was found to be 0.57, 0.5, 0.23 for ft‡kjt best forecast of f t‡k established on data up to time t
ft‡k pseudo-output
nonlinear adaptive PID control, linear adaptive PID control
and uncontrolled cases, respectively. In the present work, the
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Correspondence concerning this paper should be addressed to Professor
M. Alpbaz, Ankara University, Faculty of Engineering, Department of
Chemical Engineering, Tandog an, Ankara 06100, Turkey.
E-mail: alpbaz@eng.ankara.edu.tr
ACKNOWLEDGEMENTS The manuscript was received 11 January 2002 and accepted for
The authors gratefully acknowledge Ankara University Research Fund publication after revision 11 July 2003.
and Biotechnology Institute for providing nancial support.