Evaluation of sensors for the control of a continuous ethanol fermentation

A method is presented for the evaluation of sensors used in the control of continuous fermentations. Simulations of open-loop response to input disturbance provided a starting point for the choice of sensor type. This was evaluated quantitatively through a sensitivity ratio. It was shown that in the case of ethanol fermentation, there existed three regions where different sensors could be used for the process control depending on the inlet sugar concentration. Sugar sensors were preferable above an inlet sugar concentration of 50 kg/m³, while ethanol sensors were preferable below 25 kg/m³. In the intermediate region, sugar and ethanol sensors demonstrated equally good performance. A controllability study of a continuous ethanol fermentation was also made. A single-stage continuous stirred-tank fermentor was simulated operating at a dilution rate of 0.1 1/h and inlet glucose concentration of 160 kg/m³. The outlet glucose concentration was controlled with a PI controller. Mean square error of the controller input signal during the first five hours after introducing input disturbance was taken as a measure of the controllability. This was studied in the relation to the two key sensor characteristics, sampling time and accuracy.List of Symbols c _p kg/m³ ethanol concentration - c _p kg/m³ fermentor ethanol concentration corresponding to c _si and D - c _s kg/m³ substrate (glucose) concentration - c _s kg/m³ fermentor glucose concentration corresponding to c _si and D - c _si kg/m³ inlet substrate (glucose) concentration - c _si kg/m³ inlet glucose concentration value used for sensitivity evaluation - c _sm kg/m³ glucose concentration — measured value - c _ss kg/m³ glucose concentration setpoint value - c _x kg/m³ biomass concentration - D 1/h dilution rate - D 1/h dilution rate value used for sensitivity evaluation - D _i 1/h dilution rate at ith sampling interval - D ₀ 1/h dilution rate at steady state - K _c m³/kgh controller gain - K _p kg/m³ product inhibition constant - K _s kg/m³ Monod constant - n ₁, n ₂ random numbers - r _p kg/m³ h ethanol production rate - r _s kg/m³ h substrate (glucose) consumption rate - r _x kg/m³ h biomass growth rate - vector of independent variables - y _i ith dependent variable - Y _ps ethanol yield - Y _xs biomass yield - parameter vector - _j jth parameter - _ij sensitivity of y_i with respect to _j - _p sensitivity of fermentor ethanol concentration - _s sensitivity of fermentor glucose concentration - sensitivity ratio - c _p kg/m³ ethanol concentration difference corresponding to a change of c _si by 5% - c _s kg/m³ glucose concentration difference corresponding to a change of c _si by 5% - c _si kg/m³ concentration difference added to c _si - _i kg/m³ error at ith sampling interval - 1/h specific growth rate - _m 1/h maximum specific growth rate - _s kg/m³ standard deviation of monitored glucose concentration - _I h min kg/m³ integral time - _s min sampling period The Swedish Ethanol Foundation and the National Board for Technical Development (NUTEK) are kindly acknowledged for the financial support of this project. The authors wish to thank Peter Warkentin for the linguistic advice.