Dynamic bifurcations in continuous process of bioethanol production under aerobic conditions using Saccharomyces cerevisiae

A novel kinetic model for a cocoa waste fermentation to ethanol reaction and its experimental validation

A non-segregated kinetic model is proposed to describe a fermentation process of agro-industrial residues derived via cocoa (mucilage juice) by Pichia kudriavzevii. The novel proposed hybrid model is based on a multiple coupling reaction mechanisms (structured) to describe the kinetics of substrate consumption, biomass, carbon dioxide, and ethanol, coupled to an unstructured model for the activity enzyme. The parameters of the kinetic model are estimated by non-linear least-squares curve fitting using the Marquardt-Levenberg algorithm. In addition, numerical simulations were compared with the experimental data via residual graphs. The effectiveness of the model was statistically evaluated using dimensionless efficiency coefficients under different initial conditions. A global sensitivity analysis was applied (Fisher's information matrix). The experimental results of the batch reactor showed a maximum ethanol concentration of 29 g/L, with a yield of 0.48 g-ethanol/g-glucose and a productivity of 0.30 g/L h. The method determined that the cell formation coefficient and the specific substrate consumption rate (θ1 and θ2) directly influence most of the states of our system. The proposed scheme is particularly suitable to assist in the rational design of cell factory properties or fermentation processes because it can represent the complex biochemistry in more detail and under different initial experimental conditions; the above reveals that the generated model is robust and can be considered for control and optimization purposes.

Comparative Analysis of a Family of Sliding Mode Observers under Real-Time Conditions for the Monitoring in the Bioethanol Production

Online monitoring of fermentation processes is a necessary task to determine concentrations of key biochemical compounds, diagnose faults in process operations, and implement feedback controllers. However, obtaining the signals of all-important variables in a real process is a task that may be difficult and expensive due to the lack of adequate sensors, or simply because some variables cannot be directly measured. From the above, a model-based approach such as state observers may be a viable alternative to solve the estimation problem. This work shows a comparative analysis of the real-time performance of a family of sliding-mode observers for reconstructing key variables in a batch bioreactor for fermentative ethanol production. These observers were selected for their robust performance under model uncertainties and finite-time estimation convergence. The selected sliding-mode observers were the first-order sliding mode observer, the proportional sliding mode observer, and the high-order sliding mode observer. For estimation purposes, a power law kinetic model for ethanol production by Saccharomyces cerevisiae was performed. A hybrid methodology allows the kinetic parameters to be adjusted, and an approach based on inference diagrams allows the observability of the model to be determined. The experimental results reported here show that the observers under analysis were robust to modeling errors and measurement noise. Moreover, the proportional sliding-mode observer was the algorithm that exhibited the best performance.

Continuous removal of ethanol from dilute ethanol-water mixtures using hot microbubbles

Product inhibition is a barrier to many fermentation processes, including bioethanol production, and is responsible for dilute product streams which are energy intensive to purify. The main purpose of this study was to investigate whether hot microbubble stripping could be used to remove ethanol continuously from dilute ethanol-water mixtures expected in a bioreactor and maintain ethanol concentrations below the inhibitory levels for the thermophile Parageobacillus thermoglucosidasius (TM242), that can utilize a range of sugars derived from lignocellulosic biomass. A custom-made microbubble stripping unit that produces clouds of hot microbubbles (~120 °C) by fluidic oscillation was used to remove ethanol from ~2% (v/v) ethanol-water mixtures maintained at 60 °C. Ethanol was continuously added to the unit to simulate microbial metabolism. The initial liquid height and the ethanol addition rate were varied from 10 to 50 mm and 2.1-21.2 g h^-1 respectively. In all the experiments, ethanol concentration was maintained well below the inhibition threshold of the target organism (~2% [v/v]). This microbubble stripping unit has the potential to operate in conjunction with a 0.5-1.0 L fermenter to allow an ethanol productivity of 14.9-7.8 g L^{- 1}h^-1 continuously.

Stability and Performance Analysis of Bioethanol Production with Delay and Growth Inhibition in a Continuous Bioreactor with Recycle

This paper proposes and analyzes a mathematical model for the production of bioethanol in a continuous bioreactor with recycling. The kinetics correspond to the use of Saccharomyces bayanus for the fermentation of sugars found in wastewater from soft drinks. The proposed model considers product growth latency, which was experimentally found in batch studies of ethanol production. Furthermore, the inhibition effect of ethanol is expressed by a modified version of the classical Andrew’s model for substrate inhibition. The proposed model consists of only three ordinary differential equations containing a minimal number of operating parameters, which include the bioreactor residence time, glucose feed concentration, recycle ratio and the fraction of biomass removed from the reactor by the flow. The positivity and the boundedness of solutions of the model were confirmed under reasonable restrictions of parameters. The stability analysis showed that there is a value of residence time at which an exchange of stability occurs between the trivial washout and non-washout solutions. This critical value depends only on the substrate feed concentration, biomass death rate, recycle ratio and purge fraction. Dynamic simulations of the model were carried out for substrate concentration in the range of 100–250 g/L, commonly used for the production of ethanol. An inverse response due to the inhibition effects of ethanol was observed in the time evolution of substrate and biomass concentrations. Parametric studies showed that ethanol concentration increases with the recycle ratio, with the inverse of residence time and with the inverse of purge fraction. The effect of ethanol latency has, on the other hand, a substantial effect on ethanol concentration. Despite its unstructured nature and the fact that some parameters such as temperature and acidity were not taken into consideration, the proposed model managed to provide useful results on the bioreactor-settler stability and the effect of key parameters on its dynamic behavior, which could pave the way for future optimization studies.

Optimisation of Energy Use in Bioethanol Production Using a Control Algorithm

In this work, the possibility of limiting energy consumption in the manufacturing process of bioethanol to obtain biofuel was analysed. For this purpose, a control algorithm has been optimised while retaining the good quality of the control signals. New in this study is the correlation of the control algorithm not only with the signal’s quality, but also with the energy consumption in such an energy-intensive process as rectification. The rectification process in a periodic production system has been researched. The process was modelled on a test station with the distillation mixture capacity of 25 dm3. For the optimization, the following control algorithms have been applied: relay, PID and PID after modification to I-PD. The simulation was carried out on a transfer function model of the plant that has been verified on a real object, a rectification column. The simulations of energy consumption and control signal’s quality have been carried out in the Matlab®-Simulink environment after implementing the model of the research subject and control algorithms. In the simulation process, an interference signal with an amplitude of 3% and frequency of 2 mHz was used. The executed analyses of the control signal quality and the influence of the control algorithm on the energy consumption has shown some essential mutual relationships. The lowest energy consumption in the rectification process can be achieved using the I-PD controller—however, the signal quality deteriorates. The energy savings are slightly lower while using the PID controller, but the control signal quality improves significantly. From a practical point of view, in the considered problem the best control solution is the classic PID controller—the obtained energy effect was only slightly lower while retaining the good quality of the control signals.