This document discusses bioprocess control for cell cultivation systems. It covers various parameters that are measured for control, including cell inputs and outputs, substrate levels, oxygen, carbon dioxide, temperature, pH, dissolved oxygen, and foam. Sensors used for online measurement of these parameters in bioreactors are also outlined. The document then describes basic feedback loops and controllers for bioprocess control, including PID and model predictive control. It concludes with an overview of using a supervisory control and data acquisition (SCADA) system connected over Ethernet for monitoring and controlling bioreactor systems.

1. Bioprocess Control(On-line, off-line and in-line)14th. July 2010CEPP, UTM Skudai, JohorProf. Dr. Hesham A. El EnshasyFaculty of Chemical EngineeringCEPP, UTM, Skudai, Malaysia

2. Main Items of PresentationCell Input and Cell out-put (conditions and nutrients requirements)Parameters for measurements and control for cultivation systemSensors used for bioreactors Feed back loops for bioprocess control Summary screen for different control system SCADA system for control using ethernet platform

3. Cell In-put and Cell Out-put

4. Substrate(s) Input and OutputOxygenCarbon dioxide Carbon and Energy Sources BiomassCELLMetabolite(s)Nitrogen SourceWater Other requirements(P, S,Na,K,Mg,etc…)Heat

5. Different Parameters for cultivation system

6. Integrated of Mathematical Methods for Advanced Process Control Ref. (Clementschitsch and Bayer. Microbial Cell Factories 5:19 (2006)

7. Input and Output of Bioreactor system (General overview)

8. Main in situ sensors used for measuring cultivation parameters

9. Exhaust gasAnalyzerFeed pump(s)pHTemperatureDOAerationPressurePower consumptionWeight / volumeStirrer SpeedMeasurement and open or closed loop controlMeasurement onlyCommon measurement and control of bioreactors as generally accepted as routine equipment

11. Lower ports for in situ sterilizable STR

12. Upper/lower ports and Headplate

13. pH values of different liquids

14. pH and hydrogen ion concentration

15. pH measuring circuit and pH meter construction

16. Temperature Effect on pH value

17. Temperature Error Table

18. DO meter construction

19. The relation between DO and Temperature

20. Standard Antifoam SensorType of foam: Early foaming Late foamingAntifoam effects on: DO Growth morphology (Filamentous MO)Foam sensors: Low foam sensor High foam sensor

21. On-line cell mass determination methods

22. On-line cell mass and viability measurementTheory: Cells with intact plama membranes act like tiny capacitors under the influence of electric field. The nonconducting nature of plasma membranes allows charge to build up. The resulting capacitance can be measured and is usually expressed in picofarad per centimeter (pF/cm). It depends on the cell type and is directly proportional to membrane bound volume of viable cells.

23. Controlling stat-culture

24. Feedback and Feedforward controllersFeedback control:A control algorithm to reduce the error between the set point and the controlled variable (most often PID or model predictive controller algorithm is used)Feedforward control: A computation of the manipulated variable from a measurement of the disturbance (most often corrected by a PID or model predictive controller)

25. Basic feedback loops for a fungal culture for antibiotic production

26. Basic feedback loops for microbial high cell density formation

27. Bioreactor Input and Output for basic PID control feed

33. Connections to USB, controller software and Ethernet for SCADA

34. Supervisory Control and Data Acquisition syste (SCADA)

35. Thank You