Modeling and Predictive Control of a Rotating Disk Bioreactor

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Modeling and Predictive Control of a Rotating
Disk Bioreactor

• M. Kuure-Kinsey, D. Weber, H.R. Bungay,
• J.L. Plawsky, B.W. Bequette

• Motivation
• Bioreactor Model Experimental Verification
• MPC Simulations
• Summary / Future Work

ACC 09 June 2005
Chemical and Biological Engineering
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Bacterial Cellulose

• High-strength properties
• Speaker cones
• Specialty paper
• Food
• Wound dressings (Xylos)

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Previous Work
Demonstrated feasibility of producing cellulose
with embedded particles
Semi-batch mode
Mormino and Bungay, App. Microbiol Biotechnol
(2003)
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Potential Uses
Medical coverings such as wound dressings or
artificial skin with time-release particles
Encoding of paper with a particle signature to
prevent counterfeiting
Particles to which enzymes are immobilized to
carry out sequential bioreactions
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Model
Volume Particle Conc. in Solution Cellulose
Mass in Gel Glucose Conc. In Solution Particle
Mass in Gel
Inputs FH, FD, FO Measured
Outputs V, xp
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Model Verification
Model matches experimental data on particle
concentration
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Model Verification
Model matches experimental data on cellulose
thickness
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Model Verification
Particle uptake rate accurately predicted
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Simulations

• Two operating modes continuous and semi-batch
• MPC DMC and Augmented State Space with Kalman
  Filter
• The following simulations are for a more
  detailed model than the Proceedings paper
• For brevity, not all states are shown

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EKF-based MPC
Augmented State Space Formulation
Predictor / Corrector
Prediction Horizon 15 Control Horizon
1 Sample Time 5
Disturbance Magnitude 10
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Simulations Operating Mode
Extra DOF with continuous reactor allows better
control
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Simulations Setpoint Tracking
Setpoint tracking allows bands of particles to
be formed
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Simulations Input Disturbance Rejection
Augmented formulation is able to reject
disturbances
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Simulations Residence Times
Residence times play an important role in
response time
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Summary

• Cellulose with embedded particles
• Model accounts for solution and gel phases and
  accurately matches experimental data
• Augmented state space KF-based MPC

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Future Work

• Distributed concentration of particles in gel
• Complete continuous bioreactor fabrication
• Experiments

• Scale-up and reactor design

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Acknowledgements
BES-04 Pete Gostomski Albany Pump
Station