Optimal control of fed-batch fermentation processes

Optimisation of a fed-batch fermentation process typically uses the calculus of variations or Pontryagin's maximum principle to determine an optimal feed rate profile. This often results in a singular control problem and an open loop control structure. The singular feed rate is the optimal feed rate during the singular control period and is used to control the substrate concentration in the fermenter at an optimal level. This approach is supported by biological knowledge that biochemical reaction rates are controlled by the environmental conditions in the fermenter; in this case, the substrate concentration. Since an accurate neural net-based on-line estimation of the substrate concentration has recently become available and is currently employed in industry, we are therefore able to propose a method which makes use of this estimation. The proposed method divides the optimisation problem into two parts. First, an optimal substrate concentration profile which governs the biochemical reactions in the fermentation process is determined. Then a controller is designed to track the obtained optimal profile. Since the proposed method determines the optimal substrate concentration profile, the singular control problem is therefore avoided because the substrate concentration appears nonlinearly in the system equations. Also, the process is then operated in closed loop control of the substrate concentration. The proposed method is then called "closed loop optimal control". The proposed closed loop optimal control method is then compared with the open loop optimal feed rate profile method. The comparison simulations from both primary and secondary metabolite production processes show that both methods give similar performance in a case of perfect model while the closed loop optimal control provides better performance than the open loop method in a case of plant/model mismatch. The better performance of the closed loop optimal control is due to an ability to compensate for the modelling errors using feedback

Iterative design of dynamic experiments in modeling for optimization of innovative bioprocesses

Finding optimal operating conditions fast with a scarce budget of experimental runs is a key problem to speed up the development and scaling up of innovative bioprocesses. In this paper, a novel iterative methodology for the model-based design of dynamic experiments in modeling for optimization is developed and successfully applied to the optimization of a fed-batch bioreactor related to the production of r-interleukin-11 (rIL-11) whose DNA sequence has been cloned in an Escherichia coli strain. At each iteration, the proposed methodology resorts to a library of tendency models to increasingly bias bioreactor operating conditions towards an optimum. By selecting the ‘most informative’ tendency model in the sequel, the next dynamic experiment is defined by re-optimizing the input policy and calculating optimal sampling times. Model selection is based on minimizing an error measure which distinguishes between parametric and structural uncertainty to selectively bias data gathering towards improved operating conditions. The parametric uncertainty of tendency models is iteratively reduced using Global Sensitivity Analysis (GSA) to pinpoint which parameters are keys for estimating the objective function. Results obtained after just a few iterations are very promising.Fil: Cristaldi, Mariano Daniel. Consejo Nacional de Investigaciones Científicas y Técnicas. Centro Científico Tecnológico Conicet - Santa Fe. Instituto de Desarrollo y Diseño. Universidad Tecnológica Nacional. Facultad Regional Santa Fe. Instituto de Desarrollo y Diseño; ArgentinaFil: Grau, Ricardo José Antonio. Consejo Nacional de Investigaciones Científicas y Técnicas. Centro Científico Tecnológico Conicet - Santa Fe. Instituto de Desarrollo Tecnológico para la Industria Química. Universidad Nacional del Litoral. Instituto de Desarrollo Tecnológico para la Industria Química; ArgentinaFil: Martínez, Ernesto Carlos. Consejo Nacional de Investigaciones Científicas y Técnicas. Centro Científico Tecnológico Conicet - Santa Fe. Instituto de Desarrollo y Diseño. Universidad Tecnológica Nacional. Facultad Regional Santa Fe. Instituto de Desarrollo y Diseño; Argentin

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

State estimation and trajectory tracking control for a nonlinear and multivariable bioethanol production system

In this paper a controller is proposed based on linear algebra for a fed-batch bioethanol production process. It involves fnding feed rate profles (control actions obtained as a solution of a linear equations system) in order to make the system follow predefned concentration profles. A neural network states estimation is designed in order to know those variables that cannot be measured. The controller is tuned using a Monte Carlo experiment for which a cost function that penalizes tracking errors is defned. Moreover, several tests (adding parametric uncertainty and perturbations in the control action) are carried out so as to evaluate the controller performance. A comparison with another controller is made. The demonstration of the error convergence, as well as the stability analysis of the neural network, are included.Fil: Fernández, Maria Cecilia. Universidad Nacional de San Juan. Facultad de Ingeniería. Instituto de Ingeniería Química; ArgentinaFil: Pantano, Maria Nadia. Universidad Nacional de San Juan. Facultad de Ingeniería. Instituto de Ingeniería Química; Argentina. Consejo Nacional de Investigaciones Científicas y Técnicas; ArgentinaFil: Rossomando, Francisco Guido. Consejo Nacional de Investigaciones Científicas y Técnicas. Centro Científico Tecnológico Conicet - San Juan. Instituto de Automática. Universidad Nacional de San Juan. Facultad de Ingeniería. Instituto de Automática; ArgentinaFil: Ortiz, Oscar Alberto. Universidad Nacional de San Juan. Facultad de Ingeniería. Instituto de Ingeniería Química; ArgentinaFil: Scaglia, Gustavo Juan Eduardo. Universidad Nacional de San Juan. Facultad de Ingeniería. Instituto de Ingeniería Química; Argentina. Consejo Nacional de Investigaciones Científicas y Técnicas; Argentin

Advances and Future Perspectives

Agharafeie , R., Ramos, J. R. C., Mendes, J. M., & Oliveira, R. M. F. (2023). From Shallow to Deep Bioprocess Hybrid Modeling: Advances and Future Perspectives. Fermentation, 9(10), 1-22. [922]. https://doi.org/10.20944/preprints202310.0107.v1, https://doi.org/10.3390/fermentation9100922--- This work was supported by the Associate Laboratory for Green Chemistry - LAQV which is financed by national funds from FCT/MCTES (UIDB/50006/2020 and UIDP/50006/2020). This work received funding from the European Union’s Horizon 2020 research and innovation program under the grant agreement no. 101099487- BioLaMer-HORIZON-EIC-2022-PATHFINDEROPEN-01 (BioLaMer)Deep learning is emerging in many industrial sectors in hand with big data analytics to streamline production. In the biomanufacturing sector, big data infrastructure is lagging comparatively to other industries. A promising approach is to combine Deep Neural Networks (DNN) with prior knowledge in Hybrid Neural Network (HNN) workflows that are less dependent on the quality and quantity of data. This paper reviews published articles over the past 30 years on the topic of HNN applications to bioprocesses. It revealed that HNNs were applied to various bioprocesses, including microbial cultures, animal cells cultures, mixed microbial cultures, and enzyme biocatalysis. HNNs were mainly applied for process analysis, process monitoring, development of software sensors, open- and closed-loop control, batch-to-batch control, model predictive control, intensified design of experiments, quality-by-design, and recently for the development of digital twins. Most previous HNN studies combined shallow Feedforward Neural Networks (FFNNs) with physical laws, such as macroscopic material balance equations, following the semiparametric design principle. Only recently, deep HNNs based on deep FFNNs, Convolution Neural Networks (CNN), Long Short-Term Memory (LSTM) networks and Physics Informed Neural Networks (PINNs) have been reported. The biopharma sector is currently a major driver but applications to biologics quality attributes, new modalities, and downstream processing are significant research gaps.publishersversionpublishe

Batch-to-batch iterative learning control of a fed-batch fermentation process

PhD ThesisRecently, iterative learning control (ILC) has been used in the run-to-run control of batch processes to directly update the control trajectory. The basic idea of ILC is to update the control trajectory for a new batch run using the information from previous batch runs so that the output trajectory converges asymptotically to the desired reference trajectory. The control policy updating is calculated using linearised models around the nominal reference process input and output trajectories. The linearised models are typically identified using multiple linear regression (MLR), partial least squares (PLS) regression, or principal component regression (PCR). ILC has been shown to be a promising method to address model-plant mismatches and unknown disturbances. This work presents several improvements of batch to batch ILC strategy with applications to a simulated fed-batch fermentation process. In order to enhance the reliability of ILC, model prediction confidence is incorporated in the ILC optimization objective function. As a result of the incorporation, wide model prediction confidence bounds are penalized in order to avoid unreliable control policy updating. This method has been proven to be very effective for selected model prediction confidence bounds penalty factors. In the attempt to further improve the performance of ILC, averaged reference trajectories and sliding window techniques were introduced. To reduce the influence of measurement noise, control policy is updated on the average input and output trajectories of the past a few batches instead of just the immediate previous batch. The linearised models are re-identified using a sliding window of past batches in that the earliest batch is removed with the newest batch added to the model identification data set. The effects of various parameters were investigated for MLR, PCR and PLS method. The technique significantly improves the control performance. In model based ILC the weighting matrices, Q and R, in the objective function have a significant impact on the control performance. Therefore, in the quest to exploit the potential of objective function, adaptive weighting parameters were attempted to study the performance of batch to batch ILC with updated models. Significant improvements in the stability of the performance for all the three methods were noticed. All the three techniques suggested have established improvements either in stability, reliability and/or convergence speed. To further investigate the versatility of ILC, the above mentioned techniques were combined and the results are discussed in this thesis

Control Implementation in Bioprocess System: A Review.

Bioprocess control consists of establishing a strategy for the management of the biocatalyst environment. Bioprocesses include several different units in which a near optimal environment is desired for microorganisms to grow, multiply, and produce a desired product