COMPUTER APPLICATIONS IN FERMENTATION …978-94-009-1141-3/1.pdfPapers and posters presented at the Fourth International Conference on Computer Applications in Fermentation Technology

COMPUTER APPLICATIONS IN FERMENTATION TECHNOLOGY:

Modelling and Control of Biotechnological Processes

Papers and posters presented at the Fourth International Conference on Computer Applications in Fermentation Technology held at the University of Cambridge, UK,

25-29 September 1988

Organiser and Sponsor The Society of Chemical Industry-Biotechnology Group

International Co-sponsors The European Federation of Biotechnology (EFB) The International Federation of Automatic Control (IFAC)

National Co-sponsors The Institution of Chemical Engineers The Institution of Electrical Engineers The Institute of Measurement and Control The Institution of Mechanical Engineers

Industrial Sponsors Biotechnology Computer Systems Ltd, Celltech Ltd, Glaxo Group Research Ltd, leI pic, LH Fermentation Ltd

National Organising Committee T. J. Bonham Carter (Chairman) M. B. Beck S. W. Carleysmith N. M. Fish R. I. Fox (International Programme Chairman) J. P. R. Herrmann J. A. Howell J. R. Leigh D. A. Linkens J. Lock (Secretary) N. F. Thornhill

Corresponding Member of the National Organising Committee K. Schiigerl

International Programme Committee M. B. Beck B. C. Buckland S. W. Carleysmith C. L. Cooney N. M. Fish R. I. Fox (Chairman) A. Halme (IFAC Representative) J. A. Howell A. Johnson (IFAC Representative)

J. R. Leigh D. A. Linkens J. A. Roels K. Schiigerl N. F. Thornhill P. C. Young

IFAC

~

COMPUTER APPLICATIONS IN FERMENTATION

TECHNOLOGY: Modelling and Control

of Biotechnological Processes

Edited by

N. M. FISH SERC Centre for Biochemical Engineering,

University College London, UK

R. I. FOX RHM Research Ltd, High Wycombe, UK

N. F. THORNHILL Department of Electronic and Electrical Engineering,

University College London, UK

Published for the SCI SOCIETY OF CH~~ICAL INDUSTRY

ELSEVIER APPLIED SCIENCE CHEMISTR~~~;;HREE~:i~\;~~:~~c~~ LONDON and NEW YORK

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WITH 21 TABLES AND 220 ILLUSTRATIONS

© 1989 SOCIETY OF CHEMICAL INDUSTRY Softcover reprint of the hardcover 1st edition 1989

British Library Cataloguing in Publication Data

Computer applications in fermentation technology. I. Industrial fermentation. Applications of computer systems 1. Fish, N. M. II. Fox, R. I. III. Thornhill, N. F. 660.2'8449'02854

ISBN-13:978-94-0l 0-7006-5 e-ISBN -13: 978-94-009-1141-3 DOr: 10.1007/978-94-009-1141-3

Library of Congress CIP data applied for

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products, instructions or ideas contained in the material herein.

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All rights reserved_ No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or

otherwise, without the prior written permission of the publisher.

CONTENTS

List of Authors

Introduction R. I. Fox

PART 1:

v

MEASUREMENT

Integrated fermentor sampling and analysis D.R. Omstead and R.L. Greasham

Measurement of biological reaction rates using advanced pH control systems S. Shioya

Morphological measurements on filamentous microorganisms by image analysis H.L. Packer, M.T. Belmar Campero and C.R. Thomas

Reconciliation of measurement data in fermentation using on-line expert system M.N. Karim and A. Halme

Glucose biosensors for the study and control of bakers compressed yeast production J. Bradley, P.A. Anderson, A.M. Dear, R.E. Ashby and A.P.F. Turner

Computer controlled system for on-line monitoring of a fermentation process J. Nielsen, K. Niko1ajsen and J. Vi11adsen

PART 2: MODELLING I

Structured modelling of bioreactor systems M. Reuss

xi

1

5

15

23

37

47

53

61

VI

Mathematical simulation of anaerobic stratified biofi1m processes Fang Ming, J.A. Howell and M. Canovas-Diaz

A new approach for development of structured growth models K.-H. Be11gardt, N. Hopf, R. Luttmann, W.-D. Deckwer

Modelling secondary metabolite production - case p1euromu1in A. Moser and H. Schneider

Modelling of kinetics, mass transfer and mixing phenomena in 45, 450 and 4500 L tank fermenters E. Heinz1e, T. Kaufmann, and M. Griot

A software tool for fermentation modelling D. Pardo and JP. Bovee

Hydrodynamic and kinetic modelling of a flocculating bioreactor with cell recycle J.A. Teixeira, M. Mota and S. Feyo de Azevedo

Modelling and simulation of naphthalene to salicylic acid fermentation process Wang Shu-qing, R.B. Wi1cockson and J. Mann

69

79

93

105

111

115

121

PART 3: MODELLING II - SYSTEM IDENTIFICATION, PARMETER AND STATE ESTIMATION

An introduction to system identification, parameter and state estimation M.B. Beck and P.C. Young

Expert system approach to recognize the state of fermentation and to diagnose faults in bioreactors A. Ha1me

Toward a systematic method for the generalization of fermentation data G.N. Stephanopou1os and C. Tsiveriotis

Adaptive inferential estimation and its application to biomass control G.A. Montague, A.J. Morris and M.T. Tham

Experimental validation of a methodology for on-line state estimation in bioreactors D. Dochain, E. de Buy1 and G. Bastin

129

159

169

179

187

Vll

Optimal feeding strategy for identification of Monod-type models by fed-batch experiments A. Munack

Identification of a simulated continuous yeast fermentation M.Y. Andersen and S.B. J_rgensen

Structured modelling and parameter identification of budding yeast populations L. Cazzador and L. Mariani

Parameter estimation of kinetics and modelling in methanogenic fermentation of Methanosarcina barkeri E.C. Ferreira, L.M. Pereira, S. Feyo de Azevedo and J.M.C. Duarte

On-line estimation of cell mass using an extended Kalman filter P.A. Montgomery and D. Williams

Observability by pH in bioprocesses M.N. Pons, L. Garrido-Sanchez and J.M. Engasser

PART 4: CONTROL I

195

205

211

217

221

227

Process controlled temperature induction during batch 235 fermentations for recombinant DNA products J.W. Brandis, D.F. Ditullio, J.F. Lee and W.B. Armiger

Application of an expert system to the operation and 253 control of industrial antibiotic fermentation process Chen Qi, Wang Shu-qing and Wang Ji-cheng

IBE fermentation control 263 &.T.J.M. van der Heij den , W.J. Groot, Ch. Hellinga, G. Honderd and K.Ch.A.M. Luyben

Improvement of the penicillin production in 277 bench-scale reactors by on-line measurement, data evaluation and parameter-adaptive control K. Schagerl, J. Moller, J. Niehoff, R. Hiddessen, K. Frah and A. Labbert

On-line parameter identification and computer control 291 of an anaerobic waste water treatment process S. Freyer, R. Eberhardt, D. Scharbascher and C. Wandrey

VIll

On experiences with expert systems in the control of bioreactors A. LUbbert, B. Hitzmann, H.-A. Kracke-Helm and K. Schllgerl

Intelligent purification of monoclonal antibodies P.W. Thompson, A.C. Kenney, P. Moulding and D. Wormald

PART 5: CONTROL II

A fed-batch process for pullulanase production D.E. Brown, P.A. Allinson and B.J. Minihane

A new approach for the control of baker's yeast fed-batch fermentation Ch. Albrecht, P. Keil and W. Chalupka

Lyapunov design of convergent adaptive controllers for a class of multilinear systems arising from biotechnological applications G. Bastin

A new nonlinear adaptive approach to automatic control of bioprocesses M. Lakrori and A. Cheruy

Adaptive algorithm for estimation and control of fed-batch bioprocesses J.M. Flaus, M.N. Pons, A. Cheruy and J.M. Engasser

Modelling and control of polygalacturonase production from Kluyveromyces marxianus J.R. Perez, D.L. Pyle, J.R. Rockey and C.A. Zaror

Nonlinear estimation and adaptive control of a fed-batch fermentor Y. Pomerleau and M. Perrier

Sensitivity analysis in static optimization of fermentation plants C. Posten

Maximum production of glutathione in fed-batch culture of Saccharomyces cerev~s~ae H. Shimizu, K. Araki, M. Ogura, S. Shioya, K. Suga and E. Sada

297

303

311

32l

331

341

349

355

361

367

373

IX

PART 6: DATA MANAGEMENT

Management of process control data for bio-process analysis R. C.J. Fewkes

Data handling for fermentation development - an industrial approach S . W. Car 1eysmi th

On-line monitoring of the response of a fermentation process to nutrient additions B.C. Buckland

A modelling approach to trouble diagnosis by multilevel fuzzy functions and its application Fu Chunsheng, Wang Shu-qing and Wang Ji-cheng

Model based optimization of a SCP fermentation process S. Kotob, Ch. Albrecht and M. Juraidan

Adaptive monitoring of bioreactor contamination T. Chattaway and G.N. Stephanopou1os

PC-based on-line estimation of derived variables C.A. Kent, D.C. Hear1e, R.W. Lecky-Thompson, D.J. Wea1e, A.N. Emery and A.W. Nienow

The use of carbon dioxide evolution rate in consistency checking other fermenter sensor outputs P.N.C. Royce, M.M .. Anderson, N.M. Fish and N. F Thornhill

381

393

401

411

421

431

437

443

Using the downhill Simplex method to fit complex rate 449 equations to data v. Singh

Fermentation fault diagnosis using analytical 455 redundancy N.F Thornhill, M.Y.P. Fung, F.W. Roche, P.N.C. Royce, M.M. Anderson and N.M. Fish

Author Index 461

Subject Index 465

LIST OF AUTHORS

Albrecht, Ch.

Allinson, P.A.

Andersen, M.Y.

Anderson, M.M.

Anderson, P.A.

Araki, K.

Armiger, W.B.

Ashby, R.E.

Bastin, G.

Beck, M.B.

Bellgardt, K.-H.

Xl

Institute of Biotechnology, Academy of Sciences of the GDR, GDR

Department of Chemical Engineering, UMIST, UK current address: James River Photographic Papers Ltd, UK

Instituttet for Kemiteknik, Technical University of Denmark, Denmark

Department of Chemical and Biochemical Engineering, University College London, UK

Distillers Company (Yeast) Ltd, UK

Department of Fermentation Technology, Osaka University, Japan

BioChem Technology, Inc., USA

Biotechnology Centre, Cranfield Institute of Technology, UK

Laboratoire d'Automatique, Catholic University of Louvain, Belgium

Department of Civil Engineering, Imperial College, London, UK

Gesellschaft fur Biotechnologische Forschung mbH, FRG

Belmar Campero, M.T.

Bovee, JP.

Bradley, J.

Brandis, J.W.

Brown, D.E.

Buckland, B.C.

de Buyl, E.

Canovas-Diaz, M.

Carleysmith, S.W.

Cazzador, L.

Chalupka, W.

Chattaway, T.

Chen Qi

Cheruy, A.

Dear, A.M.

Deckwer, W.-D.

XlI


Sanofi Elf Bio-Recherches, France


Triton Biosciences, Inc., USA

Department of Chemical Engineering, UMIST, UK current address: Biotechnology Centre, Cranfield Institute of Technology, UK

Merck Sharp and Dohme Research Laboratories, USA

SOLVAY and Cie, Belgium

Department of Biochemistry, University of Murcia, Spain

Beecham Pharmaceuticals UK Division, Worthing, UK

LADSEB-CNR, Italy


Department of Chemical Engineering, Massachusetts Institute of Technology, USA

Department of Chemical Engineering, Zhejiang University, People's Republic of China

Laboratoire d'Automatique de Grenoble, ENSIEG-INPG, France

Distillers Company (Yeast) Ltd, UK

Gesellschaft fur Biotechnologische Forschung mbH, FRG

Ditullio, D.F.

Dochain, D.

Duarte, J.M.C.

Eberhardt, R.

Emery, A.N.

Engasser, J.M.

Fang Ming

Ferreira, E.C.

Fewkes, R.C.J.

Feyo de Azevedo, S.

Fish, N.M.

Flaus, J.M.

Fox, R.I.

Freyer, S.

FrUh, K.

Fu Chunsheng

XUI

Triton Biosciences, Inc., USA

Laboratoire d'Automatique, Catholic University of Louvain, Belgium

LNETI-DTIQ, Portugal

Institute of Biotechnology, Nuclear Research Centre Julich, FRG

Department of Chemical Engineering, University of Birmingham, UK

Laboratoire des Sciences du Gonie Chimique, CNRS-ENSIC-INPL, France

School of Chemical Engineering, University of Bath, UK


Eastman Kodak Bioproducts Division, USA

Centro de Engenharia Quimica da Universidade do Porto, Portugal


Laboratoire des Sciences du GOnie Chimique, CNRS-ENSIC-INPL, France

RHM Research Ltd, UK


Institut fur Technische Chemie, Universitat Hannover, FRG


Fung, M.Y.P.

Garrido-Sanchez, L.

Greasham, R.L.

Griot, M.

Groot, W.J.

Halme, A.

Hearle, D.C.

van der Heijden, R.T.J.M.

Heinzle, E.

Hellinga, Ch.

Hiddessen, R.

Hitzmann, B.

Honderd, G.

HOpf, N.

XIV

Department of Electronic and Electrical Engineering, University College London, UK

Laboratoire des Sciences du GOnie Chimique, CNRS-ENSIC-INPL, France

Merck and Company, Inc., USA

Biological Reaction Engineering Group, Chemical Engineering Laboratory (TCL), ETH, Switzerland

Department of Biochemical Engineering, Delft University of Technology, The Netherlands

Laboratory of Automation Technology, Helsinki University of Technology, Finland



Biological Reaction Engineering Group, Chemical Engineering Laboratory (TCL), ETH, Swi tzerland


Institut fUr Technische Chemie, Universitat Hannover, FRG


The Control Laboratory, Delft University of Technology, The Netherlands

Gesellschaft fUr Biotechnologische Forschung mbH, FRG

Howell, J.A.

Jplrgensen, S.B.

Juraidan, M.

Karim, M.N.

Kaufmann, T.

Keil, P.

Kenney, A.C.

Kent, C.A.

Kotob, S.

Kracke-Helm, H.-A.

Lakrori, M.

Lecky-Thompson, R.W.

Lee, J.F.

Liibbert, A.

Luttmann, R.

xv

School of Chemical Engineering, University of Bath, UK

Instituttet for Kemiteknik, Technical University of Denmark, Denmark

Kuwait Institute for Scientific Research, Kuwait

Department of Agricultural and Chemical Engineering, Colorado State University, USA

Biological Reaction Engineering Group, Chemical Engineering Laboratory (TCL), ETH, Switzerland


Oros Systems Ltd, UK


Kuwait Institute for Scientific Research, Kuwait

Institut fUr Technische Chemie, Universitit Hannover, FRG

University "Enver Hoxha" of Tirana, Albania


BioChem Technology, Inc., USA

Institut fUr Technische Chemie, Universitit Hannover, FaG

Gesellschaft fUr Biotechnologische Forschung mbH, FaG

Luyben, K.Ch.A.M.

Mann, J.

Mariani, L.

Minihane, B.J.

Moller, J.

Montague, G.A.

Montgomery, P.A.

Morris, A.J.

Moser, A.

Mota, M.

Moulding P.

Munack, A.

Niehoff, J.

Nielsen, J.

XVI


Department of Chemical Engineering, Loughborough University of Technology, UK

LADSEB-CNR, Italy and Dipartimento di Elettronica e Informatica, Universita di Padova, Italy



Microbial Technology Group, University of Newcastle-uponTyne, UK

School of Information Science and Technology, Liverpool Polytechnic, UK


Institut fur Biotechnologie, Technische Universitat Graz, Austria



Arbeitsbereich Regelungstechnik, Technische Universitat Hamburg-Harburg, FRG


Department of Biotechnology, The Technical University of Denmark, Denmark

Nienow, A.W.

Nikolajsen, K.

Ogura, M.

Omstead, D.R.

Packer, H.L.

Pardo, D.

Pereira, L.M.

Perez, J.R.

Perrier, M.

Pomerleau, Y.

Pons, M.N.

posten, C.

Pyle, D.L.

Reuss, M.

Roche, F.W.

XVll




Merck and Company, Inc., USA current address: Ortho Pharmaceutical Corporation, USA


Sanofi Elf Bio-Recherches, France


Departmento de Ingeniera Quimica, Universidad de Chile, Chile

Biotechnology Research Institute, Canada

Department of Chemical Engineering, Ecole Poly technique de Montreal, Canada

Laboratoire des Sciences du Genie Chimique, CNRS-ENSIC-INPL, France

Arbeitsbereich Regelungstechnik und Systemdynamik, Technische Universitat Hamburg-Harburg, FRG

Biotechnology Group, Department of Food Science and Technology, University of Reading, UK

Institut fur Bioverfahrenstechnik, Universitat Stuttgart, FRG

Department of Electronic and Electrical Engineering, University college London, UK

Rockey, J.S.

Royce, P.N.C.

Sada, E.

Schneider, H.

Schiigerl, K.

Schiirbiischer, D.

Shimizu, H.

Shioya, S.

Singh, v.

Stephanopoulos, G.N.

Suga, K.

Teixeira, J.A.

Tham, M.T.

Thomas, C.R.

Thompson, P.W.

XVlll


Department of Chemical and Biochemical Engineering, University college London, UK

Department of Chemical Engineering, Kyoto University, Japan

Biochemie Kundl, Austria

Institut fiir Technische Chemie, Universitat Hannover, FRG

Institute of Biotechnology, Nuclear Research Centre Jiilich, FRG

Department of Chemical Engineering, Kyoto University, Japan


Schering Corporation, USA







Thornhill, N. F .

Tsiveriotis, C.

Turner, A.P.F.

Villadsen, J.

Wandrey, C.

Wang Ji-cheng

Wang Shu-qing

Weale, D.J.

Wilcockson, R.B.

Williams, D.

Wormald, D.

Young, P.C.

Zaror, C.A.

XIX

Department of Electronic and Electrical Engineering, University College London, UK








Department of Chemical Engineering, Loughborough University of Technology, UK

School of Information Science and Technology, Liverpool Polytechnic, UK

Oros Systems Inc., USA

Environmental Science Division, Institute of Environmental and Biological Sciences, University of Lancaster, UK


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COMPUTER APPLICATIONS IN FERMENTATION …978-94-009-1141-3/1.pdfPapers and posters presented at the Fourth International Conference on Computer Applications in Fermentation Technology