Implementation of Stir-Speed Adopted Controllers Onto a Batch Bioreactor for Improved Fermentation

Quality, quantity, and economy of the fermentation product depend on the transient response and the steady-state of the fermentation process. Due to its simple construction, an industrial batch bioreactor cannot be equipped with a closed-loop control system that applies adding or removing substances during fermentation. This theoretical and practical study displays how fermentation can be controlled, in this case by altering the rotational speed of a stirrer system of such a bioreactor. A numerical analysis was employed to set up a mathematical model that describes the impact of the stirrer speed on the fermentation. The model consists of linear and non-linear parts. To determine their parameters, a least square identification and a particle swarm optimization method were utilized. The model was fitted and tested experimentally in a laboratory on the operating batch bioreactor. The design and synthesis of a conventional linear control system and an advanced model reference adaptive control system, which is also convenient for control of non-linear controlled plants, were carried out based on the determined mathematical model. Both control concepts were first implemented into the dSpace 1103 control system, convenient for faster development and prototyping. Finally, they were realized with the Siemens SIMATIC S7 programmable logic controller, which was ideal for industrial environment operation. During the operation of the bioreactor, the control systems were tested along with the acquisition of measured data involving CO2 concentration of a fermentation product. The findings of successfully applying linear and adaptive controllers of the milk fermentation in the batch bioreactor are analyzed and presented.