Professional Documents
Culture Documents
Elmar Heinzle
Irving J. Dunn
John Ingham
Jiří E. Přenosil
10 9 8 7 6 5 4 3 2 1
v
Contents
Preface xiii
Acknowledgments xxi
Nomenclature for Part I xxiii
List of Simulation Examples xxviii
1 Modeling Principles 3
1.1 Fundamentals of Modeling 3
1.1.1 Use of Models for Understanding, Design, and Optimization of
Bioreactors 3
1.1.2 General Aspects of the Modeling Approach 4
1.1.3 General Modeling Procedure 6
1.1.4 Simulation Tools 8
1.1.5 Teaching Applications 8
1.2 Development and Meaning of Dynamic Differential Balances 9
1.2.1 Derivation of a Balance Equation Using Rates 11
1.2.2 Computer Solution 12
1.3 Formulation of Mass Balance Equations 13
1.3.1 Types of Mass Balance Equations 13
1.3.2 Balancing Procedure 15
1.3.2.1 Case A: Continuous Stirred Tank Bioreactor 15
1.3.2.2 Case B: Tubular Reactor 16
1.3.2.3 Case C: River with Eddy Current 16
1.3.3 Total Mass Balances 23
1.3.4 Component Balances for Reacting Systems 24
1.3.4.1 Case A: Constant Volume Continuous Stirred Tank Reactor 25
1.3.4.2 Case B: Semicontinuous Reactor with Volume Change 26
1.3.4.3 Case C: Steady-state Oxygen Balancing in Fermentation 27
1.3.4.4 Case D: Inert Gas Balance to Calculate Flow Rates 28
1.4 Additional Relationships 29
1.4.1 Stoichiometry and Metabolite and Elemental Balancing 29
vi Contents
3 Biological Kinetics 57
3.1 Enzyme Kinetics 58
3.1.1 Reaction Equilibrium 58
3.1.2 Michaelis–Menten Equation 58
3.1.3 Other Enzyme Kinetic Models 61
3.1.3.1 Double Michaelis–Menten Kinetics 62
3.1.3.2 Inhibition 62
3.1.3.3 Substrate Inhibition 63
3.1.3.4 Allosteric Kinetics 64
3.1.3.5 Temperature and pH Influence 64
3.1.4 Enzyme Deactivation 65
3.2 Simple Microbial Kinetics 65
Contents vii
Index 521
xiii
Preface
Our goal in this textbook is to teach, through modeling and simulation, the quan-
titative description of bioreaction processes to scientists and engineers. In working
through the many simulation examples, you, the reader, will learn to apply material
and energy balances to describe the dynamics of a variety of bioreactors and other
biological systems. For your efforts, you will be rewarded with a greater understand-
ing of the dynamics of biological processes. The many example applications will help
you to gain confidence in modeling, and you will find that the simulation language
used, Berkeley Madonna, is a powerful tool for developing your own simulation
models. Your new abilities will be valuable for designing experiments, for extract-
ing kinetic data from experiments, in designing and optimizing biological reaction
systems, and for developing bioreactor control strategies.
This book is based on our successful course, “Biological Reaction Engineering,”
which has been held annually in the Swiss mountain resort of Braunwald for many
years and which is now known, throughout international biotechnology circles as
the “Braunwald Course.” This course has been continued with a modified direction
and is now called “Biosystems Engineering: Bioreactor and Cell Factories.” Alto-
gether the course has been held for 40 years. The newer course continues using
the book but putting more emphasis on modeling cellular systems and their reac-
tor environment. This third edition provides an excellent basis for teaching systems
biology principles. More details on the course can be found at our website: http://
www.braunwald-bioengineering.de.
Modeling is often unfamiliar to biologists and chemists, who nevertheless need
modeling techniques in their work. The general field of biochemical reaction
engineering is one that requires a very close interdisciplinary interaction between
applied microbiologists, biologists, biochemists, biochemical engineers, engineers,
bioinformaticians, and managers; a large degree of collaboration and mutual
understanding is therefore important. Microbiologists, molecular biologists, and
biochemists often lack the formal training needed to analyze laboratory kinetic
data in its most meaningful sense, and they may sometimes experience difficulty
in participating in engineering design decisions and in communicating with engi-
neers. These are exactly the types of activity required in the multidisciplinary field
of biotechnology. Chemical engineering’s greatest strength is its well-developed
xiv Preface
modeling concepts, based on material and energy balances, combined with kinetics
of reactions and of mass and energy transfer.
Biochemical engineering is a discipline closely related to conventional chemical
engineering in that it attempts to apply physical principles to the solution of biologi-
cal problems. This approach may be applied to the measurement and interpretation
of laboratory kinetic data, to metabolic network modeling, e.g. for metabolic flux
analysis or metabolic network design, or to the design of large-scale fermentation,
enzymatic or waste treatment processes. The necessary interdisciplinary cooper-
ation requires the biological scientists and chemical engineers involved to have
at least a partial understanding of each other’s fields. The purpose of this book
is to provide the mathematical tools necessary for the quantitative analysis of
biological kinetics and related biological process phenomena. More generally, the
mathematical modeling methods presented here are intended to lead to a greater
understanding of how the biological reaction systems are influenced by process
conditions.
Engineering science depends heavily on the use of applied theory, quantitative
correlations, and mathematics, and it is often difficult for all of us (not only the
biological scientist) to surmount the mathematical barrier, which is posed by engi-
neering. A mistake, often made, is to confuse “mathematics” with the engineering
modeling approach. In modeling, an attempt is made to analyze a real and possi-
bly very complex situation into a simplified and understandable physical analog.
This physical model may contain many subsystems, all of which still make physi-
cal sense, but which now can be formulated with mathematical equations. These
equations can be handled automatically by the computer. Thus, the engineer and
the biologist are freed from the difficulties of mathematical solution and can tackle
complex problems that were impossible to solve before. Models, however, still have
to be formulated and one of the most important tools of the biochemical engineer,
in this operation, is the setting up of material and energy balance equations. The
step of extracting a physical model from a complex real situation is actually the most
important and most difficult, though mostly not sufficiently treated in textbooks. It
requires a thorough understanding of physical, chemical, and biological principles
combined with a certain amount of phantasy and creativity. It may not be easy for the
biologist or biochemist to fully appreciate the importance of differential equations,
but material balance equations are not so difficult to understand, since the first law
of conservation, namely that matter can neither be created nor destroyed, is funda-
mental to all science. Material balances, when combined with kinetic rate equations,
to form simple mathematical models, can be used with very great effect as a means
of planning, conducting, and analyzing experiments. Models are especially impor-
tant as a means of obtaining a better understanding of process phenomena. A ratio-
nal and stringent approach to experimentation and design requires a considerable
knowledge of the system, which can really only be achieved using a mathematical
model. Such a model will also assist in understanding, thereby reducing costly and
time-consuming experimental work. This book attempts to demonstrate this by way
of the many detailed examples that are based on the extended scientific experience of
Preface xv
the authors. Many of the more complex examples are often taken from our scientific
publications.
The contribution made to biotechnology by the biochemical engineering modeling
approach is especially important because the basic procedure can be developed from
a few fundamental principles. A special aim of this book is to demonstrate that you
do not have to be an engineer to learn modeling and simulation. The basic concepts
of the material balance, combined with biological and enzyme kinetics, are easily
applied to describe the behavior of well-stirred tank and tubular fermenters, mixed
culture dynamics, interphase gas–liquid mass transfer, internal biofilm diffusional
limitations, and metabolic or signaling network dynamics, as demonstrated in the
computer examples supplied with this book. Such models, when solved interactively
by computer simulation, become much more understandable to non-engineers.
The Berkeley Madonna simulation language, used for the examples in this book, is
especially suitable because of its sophisticated computing power, interactive facility,
and ease of programming. The use of this digital simulation programming language
makes it possible for the reader, student and teacher, to experiment directly with
the model, in the classroom or at the desk. In this way, it is possible to immediately
determine the influence of changing various operating parameters on the bioreactor
performance – a real learning experience.
The simulation examples serve to enforce the learning process in a very effective
manner and also provide hands-on confidence in the use of a simulation language.
The readers can program their own examples, by formulating new material balance
equations or by modifying an existing example to a new set of circumstances. Thus,
by working directly at the computer, the no-longer-passive reader can experiment
directly on the bioreaction system in a very interactive way by changing parameters
and learning about their probable influence in a real situation. Because of the speed
of solution, a true degree of interaction is possible with Berkeley Madonna, allow-
ing parameters to be changed easily. Plotting the variables in any configuration is
easy during a run, and the results from multiple runs can be plotted together for
comparison. Other useful features include data fitting and optimization.
In our experience, modeling and digital simulation has proven itself to be
absolutely the most effective way of introducing and reinforcing new concepts that
involve multiple interactions. The thinking process is ultimately stimulated to the
point of solid understanding. In short, modeling makes you think!
are provided on the Wiley websites. The simulation examples in Part II provide an
excellent instructional and self-learning tool. Each of the more than 80 examples
is self-contained, including a model description, model equations, exercises, com-
puter program listing, nomenclature and references. The examples are found on
the Wiley websites: https://www.wiley-vch.de/ISBN978-3-527-32524-5 and https://
www.wiley.com/go/heinzle. The exercises range from simple parameter-changing
investigations to suggestions for writing a new program. The combined book thus
represents a synthesis of basic theory, modeling exercises, and computer-based sim-
ulation examples.
Quite apart from the educational value of the text, the introduction and use of
the Berkeley Madonna software provides the reader with the considerable practi-
cal advantage of a differential equation solution package. A screenshot guide con-
cerning the use of the software is found on the Wiley websites. Free demo versions
can be downloaded from the Berkeley Madonna website (www.berkeleymadonna
.com). These unlicensed demo versions allow running all examples that are avail-
able on Wiley websites only. Full versions can be bought there and would allow more
functionality concerning program modifications and cut and paste functions. More
details about Berkeley Madonna and useful computer platforms are briefly described
in the Appendix, and more information is provided on the Wiley websites. The Help
menu of Berkeley Madonna is very useful, and manuals can be downloaded from
their website.
Part I: “Principles of Bioreactor Modeling” covers the basic theory necessary for
understanding the computer simulation examples. This section presents the basic
concepts of material balancing, and their combination with kinetic relationships, to
establish simple biological reactor models, carefully presented in a way that should
be understandable to biologists. In fact, engineers may also find this rigorous presen-
tation of balancing to be valuable. In order to achieve this aim, the main emphasis
of the text is placed on an understanding of the physical meaning and significance
of each term in the model equations. The aim in presenting the relevant theory is
thus not to be exhaustive, but simply to provide a basic introduction to the theory
required for a proper understanding of the modeling methodology.
Chapter 1 deals with the basic concepts of modeling, the basic principles, develop-
ment and significance of differential balances, and the formulation of material and
energy balance relationships. Additional relationships are introduced: stoichiome-
try, elemental balancing, and the yield coefficient concept. Equilibrium relationships
focus on reaction equilibrium and acid-base equilibria for varying pH systems. Time
constants are introduced to assist in the order-of-magnitude analysis. Emphasis is
given to physical understanding.
Chapter 2 introduces the varied operational characteristics of the various types of
bioreactors and their differing modes of operation, with the aim of giving a qualita-
tive insight into the quantitative behavior of the computer simulation examples.
Chapter 3, on the other hand, presents enzyme and microbial kinetics. A particular
feature of the kinetic treatment is the emphasis on the use of more complex models
with interacting microorganisms and with a structured description of the cellular
behavior. Such models require much more consideration to the biology of the system
Preface xvii
during the modeling procedure, but despite their added complexity can nevertheless
also be solved with relative ease. All these models can be combined with the various
kinds of bioreactor systems. They serve as a reminder that biological reactions are
really infinitely complex.
Chapter 4 is used to derive general material balance equations, covering the many
types of fermentation tank reactors, including tubular reactors. These generalized
equations are then simplified to show their application to the differing modes of
stirred tank bioreactor operation, discussed previously and illustrated by the simu-
lation examples.
Chapter 5 explains the basic theory of interfacial mass transfer as applied to fer-
mentation systems and shows how equations for rates of mass transfer can be com-
bined with material balances, for both liquid and gas phases. A particular extension
of this approach is the combination of transfer rate and material balance equations
to models of increased geometrical complexity, as represented by large-scale air-lift
and multiple impeller fermenters.
Chapter 6 treats the cases of external diffusion to a solid surface and internal
diffusion combined with biochemical reaction, with practical application to immo-
bilized biocatalyst and biofilm systems. Emphasized here is the conceptual ease
of handling a complex reaction in a solid biocatalyst matrix. The resulting sets of
tractable differential difference equations are solved by simulation techniques in
several examples.
Chapter 7 describes the importance of control and summarizes control strategies
used for bioreaction processes. Here the fundamentals of feedback control systems
and their characteristic responses are discussed. This material forms the basis for
performing the many recommended control exercises in the simulation examples.
It also will allow the reader and simulator to develop his own control models and
simulation programs.
Chapter 8 provides a brief introduction of modeling and simulation techniques
applied to cells, tissues, and organisms.
Part II: “Dynamic Bioprocess Modeling, Dynamic Bioprocess Simulation
Examples and the Berkeley Madonna Simulation Language,” comprises Chapter 9,
with some introductory modeling exercises. Solutions for the introductory modeling
exercises are provided on the Wiley websites: https://www.wiley-vch.de/ISBN978-
3-527-32524-5 and https://www.wiley.com/go/heinzle. Chapter 10 contains the
many computer simulation examples and also an Appendix, which gives the instruc-
tions for using Berkeley Madonna (www.berkeleymadonna.com). Each example
in Chapter 10 includes a description of its physical system, the model equations,
that were developed in Part I, and a list of suggested exercises. The programs are
also found on the Wiley websites. These example exercises can be carried out for
the reader to explore the model system in detail, and it is suggested that work on
the computer exercises be done in close reference to the model equations and their
physical meaning, as described in the text. The exercises, however, are provided
simply as an idea for what might be done and are by no means mandatory or
restrictive. Working through a particular example will often suggest an interesting
variation, such as a control loop, which can then be programmed and inserted. The
xviii Preface
examples cover a wide range of application and can easily be extended by reference
to the literature. They are robust and are well tested by a variety of undergraduate
and graduate students and also by more than 500 participants who have previously
attended the Braunwald course. In tackling the exercises, we hope you would soon
come to share our conviction that, besides being very useful, computer simulation
is also fun to do.
For the third edition, the text was thoroughly revised and some of our earlier,
less relevant material was omitted. The nomenclature was completely revised,
especially using “C” as symbol for concentration and “r” for rate throughout the
book, following a suggestion of our friend Matthias Reuss from the University of
Stuttgart. We also thank him and Christoph Wittmann from the Saarland University
for their extended discussion on the content of this book and the presentation of
simulation examples. In addition, a number of new examples resulting mainly from
the authors’ latest research and teaching work were added including some examples
of modeling the current coronavirus pandemic. There was also an opportunity in
this new edition to eliminate most of the past errors and to avoid new ones as much
as possible. Chapter 1 “Modeling Principles” was enriched with an introduction
of metabolic network principles and the concept of time constants. In Chapter 3
“Biological Kinetics,” the modeling of metabolic networks is addressed and linked
to some recent case studies. In Chapter 6 “Diffusion and Biological Reaction for
Immobilized Biocatalyst Systems,” finite differencing is also applied to spherical
geometry, e.g. gaining importance for the quantitative description of spheroids of
animal or human cells applied in drug and toxicity testing. Chapter 7 “Automatic
Process Control Fundamentals” has now a new section of the measurement of pro-
cess variables that is also important for modeling control of bioreactors realistically.
The tuning of controller using simulation is also more emphasized by introducing
the application of integral error criteria. A whole new chapter is introduced,
Chapter 8 “Basic Cell and Bioreactor Models,” which addresses the basic balancing
for describing metabolic network systems in cells and cell compartments, which
are then combined with different types of bioreactors and bioreactor operation.
This chapter also links to physiologically based pharmacokinetic (PBPK), the PBPK
modeling and simulation, and its application to modern drug efficacy and toxicity
testing.
Part II is extended with a leading Chapter 9 that focuses on the structuring of
dynamic simulation problems and making the first often most difficult steps in set-
ting up a model, defining useful balance regions and their interconnections. Chapter
10 is the largest and most outstanding chapter of the book because it contains numer-
ous simulation examples, including new introductory exercise examples in bioreac-
tor model building (Section 10.1.4). Some are relatively simple and others extend to
more complex systems, e.g. for dynamic metabolic flux analysis. All examples are
completely revised and use the nomenclature as introduced in Part I to make an eas-
ier switch between parts. All simulation examples are freely available, can be easily
downloaded from the Wiley websites, and can be directly run even with freely avail-
able download versions of Berkeley Madonna both for Windows and macOS; buying
a license will enable full functionality. A special, reduced license fee is offered for
Preface xix
Acknowledgments
Symbols (Units)
A area (m2 )
a constant in logistic equation (1/s)
A magnitude of controller input signal (various)
a specific area (m2 /m3 )
b constant in logistic equation (m3 /kg s)
b constant in Luedeking–Piret relation (1/s)
B magnitude of controller output signal (various)
C concentration (kg/m3 , kmol/m3 )
cP heat capacity (kJ/kg K, kJ/mol K)
CPR carbon dioxide production rate (mol/s)
d differential operator and diameter (–, m)
D diffusivity (m2 /s)
D dilution rate (1/s)
DM dry mass of cells (kg)
DO dissolved oxygen (g/m3 , % air sat.)
E elemental composition matrix
Ea activation energy (kJ/mol K)
F flow rate (m3 /s)
f frequency in the ultimate gain method (1/s)
G gas flow rate (m3 )
H henry’s law constant (bar m3 /kg)
hi partial molar enthalpy (kJ/mol)
IAE integral absolute error (various)
ISE integral square error (various)
ITAE integral time-weighted absolute error (various)
j diffusional mass flux (kg/m2 s, mol/m2 s)
J total diffusional mass flux (kg/s and mol/s)
J total transfer rate (kg/s and mol/s)
k constant (various)
K equilibrium constant (various)
K mass transfer coefficient (1/s)
xxiv Nomenclature for Part I
Greek
Δ difference operator (–)
ΔG Gibb’s free reaction enthalpy (kJ/mol)
ΔH enthalpy change (kJ/mol or kJ/kg)
Φ Thiele modulus (–)
Σ summation operator (–)
𝛼 rate coefficient (various)
𝛽 rate coefficient (various)
𝛿 concentration difference quantity (kg/m3 )
𝜀 controller error (various)
𝜀 elasticity coefficient (–)
𝜂 effectiveness factor (–)
𝜇 specific growth rate (1/s)
𝜇m maximum growth rate (1/s)
𝜈 stoichiometric coefficient (–)
𝜌 density (kg/m3 )
𝜏 residence time (s, min, or h)
𝜏 time constant (s)
𝜕 partial differential operator (–)
Note: In all cases time can be specified in s, min, or h, in special cases also d.
Indices
– bar above symbol refers to dimensionless variable
* refers to equilibrium concentration
0 refers to initial, inlet, external, and zero order
1 refers to time t1 , outlet, component 1, tank 1, and first order
1, 2, ..., n refers to stream, volume elements, and stages
2 refers to tank 2, time t2 , and component 2
a refers to ambient, heating, or cooling temperature
A− refers to anions
A refers to component A, anions, and bulk
Ac refers to acetoin and acetoin formation
aer refers to aerobic
agit refers to agitation
anaer refers to anaerobic
app refers to apparent
ATP refers to ATP
ATP/X refers to consumption ATP for biomass formation
xxvi Nomenclature for Part I
Part I
Modeling Principles