128 research outputs found

    Productivity analysis and non-linear gain scheduling approach for multi-species bioprocesses with product inhibition

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    International audienceBioprocesses with product inhibition are known to allow species coexistence. In this work, we first study the productivity of the different possible equilibria, depending on the operating conditions, and show that single species offers the best performances. Then, we propose a control strategy to stabilize the dynamics about the desired equilibria, in presence of instability. Based on output feedback linearization, we propose a family of controllers and a gain-scheduling approach to adapt the controller. Finally, we illustrate our approach on numerical simulations, showing that the attraction basin of the closed-loop system is improved by considering the gain-scheduling approach

    Perturbation-based Control of Industrial Fed-batch Bioprocesses

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    The topic of this thesis is bioprocess control, more specifically control of industrial-scale microbial fed-batch bioprocesses. Its focus is therefore on methods which are easy to implement in an industrial setting, which gives certain limitations on sensors, actuators and control systems. The main part of the work in the thesis concerns control of the microbial substrate uptake rate by manipulation of the feed rate of liquid substrate to the bioprocess. This is an important parameter for improving process yields, as too low feed rates cause starvation of the microorganisms while too high rates lead to production of undesirable by-products. By-product formation decreases metabolic efficiency and the by-products have inhibiting effects on microbial growth and production. At high concentrations these can even halt growth completely, leading to process failure. Due to large batch-to-batch variations and the complexity of the pro- cesses, model-based control can be difficult to use in this type of system. The approach used in this thesis circumvents this problem by utilizing perturbations in the feed rate. It has previously been shown that the metabolic state with regard to substrate uptake rate can be determined by analysing the perturbation response in the dissolved oxygen level of a microbial process. In this thesis, the concept is developed through the use of perturbations at a predefined frequency. This provides a number of advantages and allows for estimation of the metabolic state through observing the perturbation frequency in the measured signal. The concept has been tested experimentally in industrial pilot and pro- duction scale. It has been demonstrated that a controller based on this concept can be used to compensate for batch-to-batch variations in feed demand and can rapidly compensate for changes in the demand. It has also been shown that the method can be used for monitoring and control in bioprocesses with a volume over 100 m3, using a low-complexity estimation algorithm suited for industrial use. The thesis also concerns mid-ranging control in non-stationary processes. A modified mid-ranging controller suited for such processes is proposed, which allows control signals to increase in unison during the course of a fed-batch process while maintaining the advantages of classical mid-ranging control. The concept can for instance be used for control of dissolved oxygen, an important process parameter in many bioprocesses. It has been successfully used for this purpose in pilot scale alongside the type of perturbationbased feed rate controller which is the main topic of this thesis, also showing how the latter can be used in conjunction with other control systems

    Bioprocess Monitoring and Control

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    Process monitoring and control are fundamental to all processes; this holds especially for bioprocesses, due to their complex nature. Usually, bioprocesses deal with living cells, which have their own regulatory systems. It helps to adjust the cell to its environmental condition. This must not be the optimal condition that the cell needs to produce whatever is desired. Therefore, a close monitoring of the cell and its environment is essential to provide optimal conditions for production. Without measurement, no information of the current process state is obtained. In this book, methods and techniques are provided for the monitoring and control of bioprocesses. From new developments for sensors, the application of spectroscopy and modelling approaches, the estimation and observer implementation for ethanol production and the development and scale-up of various bioprocesses and their closed loop control information are presented. The processes discussed here are very diverse. The major applications are cultivation processes, where microorganisms were grown, but also an incubation process of bird’s eggs, as well as an indoor climate control for humans, will be discussed. Altogether, in 12 chapters, nine original research papers and three reviews are presented

    Development of advanced monitoring and control tools for rAAV production in the insect cell system

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    "Since the first publication introducing the concept in 1972, gene therapy has had a series of success stories and setbacks. However, the recent rise of awareness, public interest, promising results in clinical trials and recent market approvals indicate that gene therapy has come to stay. Currently there is a growing interest from the biopharmaceutical industry in gene and cell therapy, mostly using viral vectors. (...)

    Development of monitoring and control systems for biotechnological processes

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    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

    Process development for platform chemical production from agricultural and forestry residues

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    As part of a bio-based economy, biorefineries are envisaged to sustainably produce platform chemicals via biochemical conversion of agricultural and forestry residues. However, supply risks, the recalcitrance of lignocellulosic biomass, and inhibitor formation during pre\uadtreatment impair the economic feasibility of such biorefineries. In this thesis, process design and assessment were developed with the aim of addressing these hurdles and improving the cost-effectiveness of lignocellulose-derived platform chemicals.To expand the feedstock base and reduce operational costs, logging residues served as underutilised and inexpensive raw material. The major impediment in converting logging residues was their high recalcitrance and low cellulose content, which resulted in low attainable ethanol titres during simultaneous saccharification and co-fermentation (SSCF). Pretreatment optimisation reduced inhibitor formation and recalcitrance, and led to enzymatic hydrolysis yields at par with those obtained for stem wood, despite the less favourable chemical composition. Upgrading logging residues with carbohydrate-rich oat hulls increased ethanol titres to >50\ua0g/L using batch SSCF at 20% WIS loadings, demonstrating the potential to further decrease downstream processing costs. To alleviate the toxicity of inhibitors generated during pretreatment, preadaptation was applied to Saccharomyces cerevisiae. Exposure to the inhibitors in the pretreated liquid fraction improved ethanol production during subsequent fermentation. Transferring the concept of preadaptation to lactic acid production by Bacillus coagulans cut the process times by half and more than doubled the average specific lactic acid productivity, showcasing how preadaptation could decrease operational costs.To assess the performance and robustness of process designs against process input variations, a multi-scale variability analysis framework was developed. The framework included models for bioprocess, flowsheet, techno-economic, and life cycle assessment. In a case study, multi-feed processes, in which solids and cells are fed to the process using model-based predictions, were more robust against variable cellulolytic activities than batch SSCFs in a wheat straw-based ethanol biorefinery. The developed framework can be used to identify robust biorefinery process designs, which simultaneously meet technological, economic, and environmental goals

    APPLICATION OF PROCESS SYSTEMS ENGINEERING TOOLS AND METHODS TO FERMENTATION-BASED BIOREFINERIES

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    Biofuels produced from lignocellulosic biomass via the fermentation platform are sustainable energy alternatives to fossil fuels. Process Systems Engineering (PSE) uses computer-based tools and methods to design, simulate and optimize processes. Application of PSE tools to the design of economic biorefinery processes requires the development of simulation approaches that can be integrated with existing, mature PSE tools used to optimize traditional refineries, such as Aspen Plus. Current unit operation models lack the ability to describe unsteady state fermentation processes, link unsteady state fermentation with in situ separations, and optimize these processes for competing factors (e.g., yield and productivity). This work applies a novel architecture of commercial PSE tools, Aspen Plus and MATLAB, to develop techniques to simulate time-dependent fermentation without and with in situ separations for process design, analyses and optimization of the operating conditions. Traditional batch fermentation simulations with in situ separations decouple these interdependent steps in a separate “steady state” reactor followed by an equilibrium separation of the final fermentation broth. A typical mechanistic system of ordinary differential equations (ODEs) describing a batch fermentation does not fit the standard built-in power law reaction kinetics model in Aspen Plus. To circumvent this challenge, a novel platform that links the batch reactor to a FORTRAN user kinetics subroutine (incorporates the ODEs) combined with component substitution (to simulate non-databank components) is utilized to simulate an unsteady state batch and in situ gas stripping process. The resulting model system predicts the product profile to be sensitive to the gas flow rate unlike previous “steady state” simulations. This demonstrates the importance of linking a time-dependent fermentation model to the fermentation environment for the design and analyses of fermentation processes. A novel platform linking the genetic algorithm multi-objective and single-objective optimizations in MATLAB to the unsteady state batch fermentation simulation in Aspen Plus through a component object module communication platform is utilized to optimize the operating conditions of a typical batch fermentation process. Two major contributions are: prior concentration of sugars from a typical lignocellulosic hydrolysate may be needed and with a higher initial sugar concentration, the fermentation process must be integrated with an in situ separation process to optimize the performance of fermentation processes. With this framework, fermentation experimentalists can use the full suite of PSE tools and methods to integrate biorefineries and refineries and as a decision-support tool to guide the design, analyses and optimization of fermentation-based biorefineries

    Continuous Biochemical Processing: Investigating Novel Strategies to Produce Sustainable Fuels and Pharmaceuticals

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    Biochemical processing methods have been targeted as one of the potential renewable strategies for producing commodities currently dominated by the petrochemical industry. To design biochemical systems with the ability to compete with petrochemical facilities, inroads are needed to transition from traditional batch methods to continuous methods. Recent advancements in the areas of process systems and biochemical engineering have provided the tools necessary to study and design these continuous biochemical systems to maximize productivity and substrate utilization while reducing capital and operating costs. The first goal of this thesis is to propose a novel strategy for the continuous biochemical production of pharmaceuticals. The structural complexity of most pharmaceutical compounds makes chemical synthesis a difficult option, facilitating the need for their biological production. To this end, a continuous, multi-feed bioreactor system composed of multiple independently controlled feeds for substrate(s) and media is proposed to freely manipulate the bioreactor dilution rate and substrate concentrations. The optimal feed flow rates are determined through the solution to an optimal control problem where the kinetic models describing the time-variant system states are used as constraints. This new bioreactor paradigm is exemplified through the batch and continuous cultivation of ÎČ-carotene, a representative product of the mevalonate pathway, using Saccharomyces cerevisiae strain mutant SM14. The second goal of this thesis is to design continuous, biochemical processes capable of economically producing alternative liquid fuels. The large-scale, continuous production of ethanol via consolidated bioprocessing (CBP) is examined. Optimal process topologies for the CBP technology selected from a superstructure considering multiple biomass feeds, chosen from those available across the United States, and multiple prospective pretreatment technologies. Similarly, the production of butanol via acetone-butanol-ethanol (ABE) fermentation is explored using process intensification to improve process productivity and profitability. To overcome the inhibitory nature of the butanol product, the multi-feed bioreactor paradigm developed for pharmaceutical production is utilized with in situ gas stripping to simultaneously provide dilution effects and selectively remove the volatile ABE components. Optimal control and process synthesis techniques are utilized to determine the benefits of gas stripping and design a butanol production process guaranteed to be profitable

    Mechanistic Modelling for Risk-Based Monitoring of Lactic Acid Bacteria Cultivations

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    Instrumentation and control of anaerobic digestion processes: a review and some research challenges

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    The final publication is available at Springer via http://dx.doi.org/10.1007/s11157-015-9382-6[EN] To enhance energy production from methane or resource recovery from digestate, anaerobic digestion processes require advanced instrumentation and control tools. Over the years, research on these topics has evolved and followed the main fields of application of anaerobic digestion processes: from municipal sewage sludge to liquid mainly industrial then municipal organic fraction of solid waste and agricultural residues. Time constants of the processes have also changed with respect to the treated waste from minutes or hours to weeks or months. Since fast closed loop control is needed for short time constant processes, human operator is now included in the loop when taking decisions to optimize anaerobic digestion plants dealing with complex solid waste over a long retention time. Control objectives have also moved from the regulation of key variables measured online to the prediction of overall process perfor- mance based on global off-line measurements to optimize the feeding of the processes. Additionally, the need for more accurate prediction of methane production and organic matter biodegradation has impacted the complexity of instrumentation and should include a more detailed characterization of the waste (e.g., biochemical fractions like proteins, lipids and carbohydrates)andtheirbioaccessibility andbiodegradability characteristics. However, even if in the literature several methodologies have been developed to determine biodegradability based on organic matter characterization, only a few papers deal with bioaccessibility assessment. In this review, we emphasize the high potential of some promising techniques, such as spectral analysis, and we discuss issues that could appear in the near future concerning control of AD processes.The authors acknowledge the financial support of INRA (the French National Institute for Agricultural Research), the French National Research Agency (ANR) for the "Phycover" project (project ANR-14-CE04-0011) and ADEME for Inter-laboratory assay financial support.Jimenez, J.; Latrille, E.; Harmand, J.; Robles MartĂ­nez, Á.; Ferrer Polo, J.; Gaida, D.; Wolf, C.... (2015). Instrumentation and control of anaerobic digestion processes: a review and some research challenges. Reviews in Environmental Science and Biotechnology. 14(4):615-648. doi:10.1007/s11157-015-9382-6S615648144Aceves-Lara CA, Latrille E, Steyer JP (2010) Optimal control of hydrogen production in a continuous anaerobic fermentation bioreactor. 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