Optimization-based control strategy for a large-scale polyhydroxyalkanoates production in a fed-batch bioreactor using a coupled PDE–ODE system

Abstract Control strategy development for fed-batch bioreactor (FBBR) plays an important role in the improvement of polyhydroxyalkanoate (PHA) production. To develop a feeding strategy for PHA production in a large-scale FBBR, an optimization-based control scheme that considers nutrient dispersion is proposed in this work. A coupled partial differential equations and ordinary differential equation model is proposed to describe the axial-dispersed nutrient and well-dispersed microbial dynamics with process constraints. An analytical model predictive control (AMPC) method that applies integrated variables of nutrients is employed to develop the real-time control system. The control objective is to regulate the PHA concentration at the updated set points by adjusting the nutrient feed rates; a process disturbance is introduced to evaluate the control robustness. Simulation experiments of a fed-batch operation are conducted to investigate the performance of the developed controller; the controlled output is designed to track the updated set points corresponding to the biomass concentration. Results of closed-loop and regulatory systems showed that the proposed control strategy could provide more productivity (33–38%) compared to the applied PI controller. The performance test demonstrates that the developed control system could apply the biomass concentration for updating set points, provide the optimal control actions that promote PHB accumulation and handle the disturbance effectively.