A State Observer Design for Simultaneous Estimation of Charge State and Crossover in Self-Discharging Disproportionation Redox Flow Batteries

This paper presents an augmented state observer design for the simultaneous estimation of charge state and crossover flux in disproportionation redox flow batteries, which exhibits exponential estimation error convergence to a bounded residual set. The crossover flux of vanadium through the porous separator is considered as an unknown function of the battery states, model-approximated as the output of a persistently excited linear system. This parametric model and the simple isothermal lumped parameter model of the battery are combined to form an augmented space state representation suitable for the observer design, which is carried out via Lyapunov stability theory including the error-uncertainty involved in the approximation of the crossover flux. The observer gain is calculated by solving a polytopic linear matrix inequality problem via convex optimization. The performance of this design is evaluated with a laboratory flow battery prototype undergoing self-discharge.Comment: arXiv admin note: text overlap with arXiv:1903.0407

Development of software sensors for on-line monitoring of bakers yeast fermentation process

Software sensors and bioprocess are well-established research areas which have much to offer each other. Under the perspective of the software sensors area, bioprocess can be considered as a broad application area with a growing number of complex and challenging tasks to be dealt with, whose solutions can contribute to achieving high productivity and high-quality products. Although throughout the past years in the field of software sensors and bioprocess, progress has been quick and with a high degree of success, there is still a lack of inexpensive and reliable sensors for on-line state and parameter estimation. Therefore, the primary objective of this research was to design an inexpensive measurement system for on-line monitoring of ethanol production during the backers yeast cultivation process. The measurement system is based on commercially available metal oxide semiconductor gas sensors. From the bioreactor headspace, samples are pumped past the gas sensors array for 10 s every five minutes and the voltage changes of the sensors are measured. The signals from the gas sensor array showed a high correlation with ethanol concentration during cultivation process. In order to predict ethanol concentrations from the data of the gas sensor array, a principal component regression (PCR) model was developed. For the calibration procedure no off-line sampling was used. Instead, a theoretical model of the process is applied to simulate the ethanol production at any given time. The simulated ethanol concentrations were used as reference data for calibrating the response of the gas sensor array. The obtained results indicate that the model-based calibrated gas sensor array is able to predict ethanol concentrations during the cultivation process with a high accuracy (root mean square error of calibration as well as the percentage error for the validation sets were below 0.2 gL-1 and 7 %, respectively). However the predicted values are only available every five minutes. Therefore, the following plan of the research goal was to implement an estimation method for continues prediction of ethanol as well as glucose, biomass and the growth rates. For this reason, two nonlinear extensions of the Kalman filter namely the extended Kalman filter (EKF) and the unscented Kalman filter (UKF) were implemented separately for state and parameter estimation. Both prediction methods were validated on three different cultivation with variability of the substrate concentrations. The obtained results showed that both estimation algorithms show satisfactory results with respect to estimation of concentrations of substrates 6 and biomass as well as the growth rate parameters during the cultivation. However, despite the easier implementation producer of the UKF, this method shows more accurate prediction results compared to the EKF prediction method. Another focus of this study was to design and implement an on-line monitoring and control system for the volume evaluation of dough pieces during the proofing process of bread making. For this reason, a software sensor based on image processing was designed and implemented for measuring the dough volume. The control system consists of a fuzzy logic controller which takes into account the estimated volume. The controller is designed to maintain the volume of the dough pieces similar to the volume expansion of a dough piece in standard conditions during the proofing process by manipulating the temperature of the proofing chamber. Dough pieces with different amounts of backers yeast added in the ingredients and in different temperature starting states were prepared and proofed with the supervision of the software sensor and the fuzzy controller. The controller was evaluated by means of performance criteria and the final volume of the dough samples. The obtained results indicate that the performance of the system is very satisfactory with respect to volume control and set point deviation of the dough pieces.Softwaresensoren und Bioprozese sind gut etablierte Forschungsgebiete, die sich gegenseitig viel befruchten können. Unter dem Blickwinkel der Softwaresensorik kann der Bioprozess als ein breites Anwendungsgebiet mit einer wachsenden Zahl komplexer und anspruchsvoller Aufgabenstellungen betrachtet werden, deren Lösung zur Erzielung hoher Produktivität und qualitativ hochwertiger Produkte beitragen kann. Obwohl in den letzten Jahren auf dem Gebiet der Softwaresensoren und des Bioprozesses rasch und mit großem Erfolg Untersuchung erzielt wurden, fehlt es immer noch an kostengünstigen und zuverlässigen Sensoren für die Online-Zustands- und Parameterschätzung. Daher war das primäre Ziel dieser Forschung die Entwicklung eines kostengünstigen Messsystems für die Online-Überwachung der Ethanolproduktion während des Kultivierungsprozesses von Backhefe. Das Messsystem basiert auf kommerziell erhältlichen Metalloxid-Halbleiter-Gassensoren. Die Headspace-Proben des Bioreaktors werden alle fünf Minuten für 10 s an der Gassensor-Anordnung vorbeigepumpt und die Spannungsänderungen der Sensoren werden gemessen. Die Signale des Gassensorarrays zeigten eine hohe Korrelation mit der Ethanolkonzentration während des Kultivierungsprozesses. Um die Ethanolkonzentrationen aus den Daten des Gassensorarrays vorherzusagen, wurde ein Hauptkomponenten-Regressionsmodell (PCR) verwendet. Für das Kalibrierungsverfahren ist keine Offline-Probenahme notwendig. Stattdessen wird ein theoretisches Modell des Prozesses genutzt, um die Ethanolproduktion zu jedem beliebigen Zeitpunkt zu simulieren. Die kinetischen Parameter des Modells werden im Rahmen der Kalibration bestimmt. Die simulierten Ethanolkonzentrationen wurden als Referenzdaten für die Kalibrierung des Ansprechverhaltens des Gassensorarrays verwendet. Die erhaltenen Ergebnisse zeigen, dass das modellbasierte kalibrierte Gassensorarray in der Lage ist, die Ethanolkonzentrationen während des Kultivierungsprozesses mit hoher Genauigkeit vorherzusagen (der mittlere quadratische Fehler der Kalibrierung sowie der prozentuale Fehler für die Validierungssätze lagen unter 0,2 gL-1 bzw. 7 %). Die vorhergesagten Werte sind jedoch nur alle fünf Minuten verfügbar. Daher war der folgende Plan der Untersuchung die Implementierung einer Schätzmethode zur kontinuierlichen Vorhersage von Ethanol sowie von Glukose, Biomasse und der Wachstumsrate. Aus diesem Grund wurden zwei nichtlineare Erweiterungen des Kalman Filters, nämlich der erweiterte Kalman Filter (EKF) und der unscented Kalman Filter (UKF), getrennt für die Zustands und Parameterschätzung implementiert. Beide 8 Vorhersagemethoden wurden an drei verschiedenen Kultivierungen mit Variabilität der Start substratkonzentrationen validiert. Die erhaltenen Ergebnisse zeigen, dass beide Schätzungsalgorithmen zufriedenstellende Ergebnisse hinsichtlich der Schätzung der Konzentrationen von Substraten und Biomasse sowie der Parameter der Wachstumsrate während der Kultivierung ermitteln. Trotz der einfacheren Implementierung des UKF zeigt diese Methode jedoch genauere Vorhersageergebnisse im Vergleich zur EKF-Vorhersagemethode. Ein weiterer Schwerpunkt dieser Untersuchung war der Entwurf und die Implementierung eines Online-Überwachungs- und Regelungssystems für die Volumenauswertung von Teigstücken während des Gärprozesses bei der Brotherstellung. Aus diesem Grund wurde ein auf Bildverarbeitung basierendes Überwachungssystem zur Messung der Teigvolumenauswertung entworfen und implementiert. Das Regelsystem besteht aus einem Fuzzy-Logic-Controller, der das gemessene Volumen für die Regelung nutzt. Die Regelung ist so ausgelegt, dass das Volumen der Teiglinge mit Werten des Volumens eines Teiglings unter Standardbedingungen während des Gärprozesses vergleicht und die Temperatur der Gärkammer entsprechend anpasst. Teiglinge mit unterschiedlichen Hefemengen in den Zutaten und verschiedenen Temperaturstartwerten wurden vorbereitet und unter Anwendung des Fuzzy-Reglers gegärt. Der Regler wurde anhand von Leistungskriterien und dem Endvolumen der Teigproben bewertet. Die erhaltenen Ergebnisse zeigen, dass die Leistung des Systems in Bezug auf die Volumenregelung und die Sollwertabweichung der Teigstücke sehr zufriedenstellend ist

Exact fuzzy observer for a baker’s yeast fermentation process

The purpose of this work is to design an exact fuzzy observer for a bioprocess switching between two different metabolic states. A continuous baker’s yeast culture is divided in two sub-models: a respiro fermentative with ethanol production and a respirative with ethanol consumption. An exact fuzzy observer model using sector nonlinearity was built for both nonlinear models; the observer gains were designed using Linear Matrix Inequalities (LMI’s). The observer premise variables depend on the state variables estimated by the fuzzy observer.Mexican Consejo Nacional de Ciencia y Tecnología (CONACYT) - programa 46358, 41148, Ph.D. scholarship 7066

Process analytical technology in food biotechnology

Biotechnology is an area where precision and reproducibility are vital. This is due to the fact that products are often in form of food, pharmaceutical or cosmetic products and therefore very close to the human being. To avoid human error during the production or the evaluation of the quality of a product and to increase the optimal utilization of raw materials, a very high amount of automation is desired. Tools in the food and chemical industry that aim to reach this degree of higher automation are summarized in an initiative called Process Analytical Technology (PAT). Within the scope of the PAT, is to provide new measurement technologies for the purpose of closed loop control in biotechnological processes. These processes are the most demanding processes in regards of control issues due to their very often biological rate-determining component. Most important for an automation attempt is deep process knowledge, which can only be achieved via appropriate measurements. These measurements can either be carried out directly, measuring a crucial physical value, or if not accessible either due to the lack of technology or a complicated sample state, via a soft-sensor.Even after several years the ideal aim of the PAT initiative is not fully implemented in the industry and in many production processes. On the one hand a lot effort still needs to be put into the development of more general algorithms which are more easy to implement and especially more reliable. On the other hand, not all the available advances in this field are employed yet. The potential users seem to stick to approved methods and show certain reservations towards new technologies.Die Biotechnologie ist ein Wissenschaftsbereich, in dem hohe Genauigkeit und Wiederholbarkeit eine wichtige Rolle spielen. Dies ist der Tatsache geschuldet, dass die hergestellten Produkte sehr oft den Bereichen Nahrungsmitteln, Pharmazeutika oder Kosmetik angehöhren und daher besonders den Menschen beeinflussen. Um den menschlichen Fehler bei der Produktion zu vermeiden, die Qualität eines Produktes zu sichern und die optimale Verwertung der Rohmaterialen zu gewährleisten, wird ein besonders hohes Maß an Automation angestrebt. Die Werkzeuge, die in der Nahrungsmittel- und chemischen Industrie hierfür zum Einsatz kommen, werden in der Process Analytical Technology (PAT) Initiative zusammengefasst. Ziel der PAT ist die Entwicklung zuverlässiger neuer Methoden, um Prozesse zu beschreiben und eine automatische Regelungsstrategie zu realisieren. Biotechnologische Prozesse gehören hierbei zu den aufwändigsten Regelungsaufgaben, da in den meisten Fällen eine biologische Komponente der entscheidende Faktor ist. Entscheidend für eine erfolgreiche Regelungsstrategie ist ein hohes Maß an Prozessverständnis. Dieses kann entweder durch eine direkte Messung der entscheidenden physikalischen, chemischen oder biologischen Größen gewonnen werden oder durch einen SoftSensor. Zusammengefasst zeigt sich, dass das finale Ziel der PAT Initiative auch nach einigen Jahren des Propagierens weder komplett in der Industrie noch bei vielen Produktionsprozessen angekommen ist. Auf der einen Seite liegt dies mit Sicherheit an der Tatsache, dass noch viel Arbeit in die Generalisierung von Algorithmen gesteckt werden muss. Diese müsse einfacher zu implementieren und vor allem noch zuverlässiger in der Funktionsweise sein. Auf der anderen Seite wurden jedoch auch Algorithmen, Regelungsstrategien und eigne Ansätze für einen neuartigen Sensor sowie einen Soft-Sensors vorgestellt, die großes Potential zeigen. Nicht zuletzt müssen die möglichen Anwender neue Strategien einsetzen und Vorbehalte gegenüber unbekannten Technologien ablegen

Takagi-Sugeno fuzzy observer for a switching bioprocess : sector nonlinearity approach

Mexican Consejo Nacional de Ciencia y Tecnología (CONACyT)

Hybrid Control of a Bioreactor with Quantized Measurements: Extended Version

We consider the problem of global stabilization of an unstable bioreactor model (e.g. for anaerobic digestion), when the measurements are discrete and in finite number ("quantized"), with control of the dilution rate. The model is a differential system with two variables, and the output is the biomass growth. The measurements define regions in the state space, and they can be perfect or uncertain (i.e. without or with overlaps). We show that, under appropriate assumptions, a quantized control may lead to global stabilization: trajectories have to follow some transitions between the regions, until the final region where they converge toward the reference equilibrium. On the boundary between regions, the solutions are defined as a Filippov differential inclusion. If the assumptions are not fulfilled, sliding modes may appear, and the transition graphs are not deterministic

Exact fuzzy observer for a baker’s yeast fed-batch fermentation process

The purpose of this work is to design an exact fuzzy observer for a bioprocess switching between two different metabolic states. A fed-batch baker's yeast culture is modeled by two sub-models: a respiro-fermentative state with ethanol production and a respirative state with ethanol consumption. An exact fuzzy observer model using sector nonlinearity was built for both nonlinear models; the observer gains were designed using Linear Matrix Inequalities (LMI's). The observer dynamics shows a very good tracking behavior with respect of the states of the switching partial models. The observer premise variables depend on the state variables estimated by the fuzzy observer.Mexican Consejo Nacional de Ciencia y Tecnología (CONACyT) - under grants 46538, 41148 and the Ph.D. Schoolarship 70662

Data-driven Soft Sensors in the Process Industry

In the last two decades Soft Sensors established themselves as a valuable alternative to the traditional means for the acquisition of critical process variables, process monitoring and other tasks which are related to process control. This paper discusses characteristics of the process industry data which are critical for the development of data-driven Soft Sensors. These characteristics are common to a large number of process industry fields, like the chemical industry, bioprocess industry, steel industry, etc. The focus of this work is put on the data-driven Soft Sensors because of their growing popularity, already demonstrated usefulness and huge, though yet not completely realised, potential. A comprehensive selection of case studies covering the three most important Soft Sensor application fields, a general introduction to the most popular Soft Sensor modelling techniques as well as a discussion of some open issues in the Soft Sensor development and maintenance and their possible solutions are the main contributions of this work

Development of monitoring and control systems for biotechnological processes

The field of biotechnology represents an important research area that has gained increasing success in recent times. Characterized by the involvement of biological organisms in manufacturing processes, its areas of application are broad and include the pharmaceuticals, agri-food, energy, and even waste treatment. The implication of living microorganisms represents the common element in all bioprocesses. Cell cultivations is undoubtedly the key step that requires maintaining environmental conditions in precise and defined ranges, having a significant impact on the process yield and thus on the desired product quality. The apparatus in which this process occurs is the bioreactor. Unfortunately, monitoring and controlling these processes can be a challenging task because of the complexity of the cell growth phenomenon and the limited number of variables can be monitored in real-time. The thesis presented here focuses on the monitoring and control of biotechnological processes, more specifically in the production of bioethanol by fermentation of sugars using yeasts. The study conducted addresses several issues related to the monitoring and control of the bioreactor, in which the fermentation takes place. First, the topic concerning the lack of proper sensors capable of providing online measurements of key variables (biomass, substrate, product) is investigated. For this purpose, nonlinear estimation techniques are analyzed to reconstruct unmeasurable states. In particular, the geometric observer approach is applied to select the best estimation structure and then a comparison with the extended Kalman filter is reported. Both estimators proposed demonstrate good estimation capabilities as input model parameters vary. Guaranteeing the achievement of the desired ethanol composition is the main goal of bioreactor control. To this end, different control strategies, evaluated for three different scenarios, are analzyed. The results show that the MIMO system, together with an estimator for ethanol composition, ensure the compliance with product quality. After analyzing these difficulties through numeric simulations, this research work shifts to testing a specific biotechnological process such as manufacturing bioethanol from brewery’s spent grain (BSG) as renewable waste biomass. Both acid pre-treatment, which is necessary to release sugars, and fermentation are optimized. Results show that a glucose yield of 18.12 per 100 g of dried biomass is obtained when the pre-treatment step is performed under optimized conditions (0.37 M H2SO4, 10% S-L ratio). Regarding the fermentation, T=25°C, pH=4.5, and inoculum volume equal to 12.25% v/v are selected as the best condition, at which an ethanol yield of 82.67% evaluated with respect to theoretical one is obtained. As a final step, the use of Raman spectroscopy combined with chemometric techniques such as Partial Least Square (PLS) analysis is evaluated to develop an online sensor for fermentation process monitoring. The results show that the biomass type involved significantly affects the acquired spectra, making them noisy and difficult to interpret. This represents a nontrivial limitation of the applied methodology, for which more experimental data and more robust statistical techniques could be helpful