control of a continuous bioreactor using model predictive control
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www.elsevier.com/locate/procbio
Process Biochemistry 40 (2005) 2763–2770
Control of a continuous bioreactor using model predictive control
S. Ramaswamy a, T.J. Cutright b, H.K. Qammar a,*
a Department of Chemical Engineering, The University of Akron, Akron, OH 44325-3906, USAb Department of Civil Engineering, The University of Akron, Akron, OH 44325-3906, USA
Received 22 April 2004; accepted 9 December 2004
Abstract
Bioreactor control has become very important in recent years due to the difficulty in controlling the highly non-linear behaviour associated
with such systems. Model predictive control (MPC) was used to control a non-linear continuous stirred tank bioreactor to an unstable steady
state, which was the desired set point. The effect of varying predictor horizon, an important MPC controller tuning parameter, was studied. As
the predictor horizon increased, the trajectory moved away from steady state towards a period attractor. The relationship between the changing
manipulated input and the system behaviour for different initial conditions as a result of the non-linearities associated with the bioreactor
dynamics was also analyzed. The results indicated that the controlled bioreactor can exhibit non-intuitive non-linear behaviour and even a
well-designed control scheme may result in very poor performance.
# 2005 Elsevier Ltd. All rights reserved.
Keywords: Model predictive control; Bioreactor; Non-linear; P horizon
1. Introduction
Previously, the control of bioreactors was restricted to the
regulation of variables, such as pH and temperature, for
optimizing the microbial growth [1]. These were the ideal
variables to control since they often have negligible
perturbations. However, variables subject to large fluctua-
tions, such as substrate regulation can be just as important
for growth optimization [2,3]. For instance, too much
substrate can be toxic while too little can force an early
stationary phase or the onset of endogenous decay (i.e.,
death by starvation). The level of substrate required will
depend on the consumption rate (a function of the species
growth rate) and on the desired end product. For example, if
a rhamnolipid biosurfactant produced from Pseudomonas
auerigenosa is desired, the system must be maintained in the
stationary phase. Therefore the key is to be able to select and
control the optimal substrate set point based on the desired
biomass concentration [4–6]. Another approach may need a
specific respiratory quotient to be maintained [7]. Both cases
require the successful use of a controller. For systems where
* Corresponding author. Tel.: +1 330 972 5917; fax: +1 330 972 5856.
E-mail address: [email protected] (H.K. Qammar).
0032-9592/$ – see front matter # 2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.procbio.2004.12.019
large biomass production is desired, a controller to enable
continuous operation with a minimal number of washout
cycles (i.e., dilution rates) would be required.
The control of bioreactors based on substrate concentra-
tion has become an interesting problem from both
implementation and controller design points of view. This
is particularly true if the complex microbial interactions
yield significant non-linear behaviour. When this occurs,
conventional control strategies may be ineffective and more
specialized strategies need to be suggested on a case-by-case
basis. Often the reasons why a controller works and the role
of the non-linear dynamics are not fully explained. Previous
studies reported various types of controller designs
including internal model control (IMC) and adaptive
controllers, which can lead to stable control [8–12]. While
these control techniques may be successful for open loop
stable processes or in the vicinity of an unstable operating
point, about which a linearization is applied, they are often
inadequate for highly unstable non-linear bioreactors.
Unstable non-linear bioreactors are commonly encountered
in fed-batch systems or processes that involve a change in
gain [7,13,14]. In this paper, an example is provided showing
how non-linear effects may result in poor control
performance causing unwanted washout or batch operation.
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S. Ramaswamy et al. / Process Biochemistry 40 (2005) 2763–27702764
There have been previous investigators of non-linear aspects
of bioreactor dynamics. Ajbar and Gamal [15] studied the
stability and bifurcation mechanisms of a non-linear
bioreactor with cell recycle. From their mathematical
analysis, they reported a range of system parameter values
that caused instability, i.e., washout. These results show the
importance of understanding the types of non-linear
behaviour possible for a given operating range. Tsao and
Wu [12] considered the dynamics for a controlled bioreactor
system. They formulated a multivariable adaptive control
algorithm on a continuous stirred tank bioreactor to control it
to a steady state within a limit cycle. They found that by
imposing bounds on the substrate flow rate and substrate
feed concentration, washout could be prevented. While these
studies emphasize the importance of avoiding washout, they
do not explain how bioreactor non-linearities lead to such
inefficient control performance.
In this paper, we have applied model predictive control
(MPC) to a model of a non-linear continuous fermentor. The
system originally developed by Agrawal et al. [16] has been
selected as a benchmark control problem. MPC has been
implemented on several difficult non-linear systems [17–19]
and is a good candidate for implementing control on a non-
linear bioreactor. The effect of an MPC control parameter,
predictor horizon has been investigated and the range that
yields stable control was determined. The predicator horizon
is used to whatever time in the future the model prediction is
required. (An in-depth review of control theory is not within
the scope of this manuscript. Additional information
pertaining to the basic concepts in model predictive control
is presented and illustrated in Bequette’s control textbook
[20].) The effect of the predictor horizon on the stability
from the underlying non-linear behaviour of the controlled
system has been explained. The MPC controlled system can
exhibit both ‘batch reactor’ mode, and washout and the
operating regions for these have been described. Knowledge
pertaining to the operating regions is critical for successful
economical control. As will be shown in this paper, the
control of a benchmark system, prevention of batch mode
and minimization of washout occurs only in a narrow
operating region.
Fig. 1. Simplified schematic of a continuous bioreactor.
2. Bioreactor control
The bioreactor model used in this paper was originally
studied by Agarwal who performed a bifurcation analysis
and determined regimes of periodic oscillations. Periodic,
sustained oscillations are a common undesirable problem
that occurs during the production of baker’s yeast [7,21].
Brengel and Seider [22] have also applied MPC to control
oscillating systems but used a linearized model. Ungar [23]
selected this as a benchmark control problem because this
system is difficult to control due to non-linearities such as
input–output multiplicities and limit cycles associated with
its behaviour.
Basically a bioreactor is a tank in which several
biological reactions occur simultaneously in a liquid
medium. In the simplest reactor two components are
considered, biomass and substrate. Biomass consists of cells
that consume the substrate. Consider the schematic of a
biochemical reactor in Fig. 1, where X and S are the cell and
substrate concentrations, F is the feed flow rate of substrate
(assuming no biomass in feed) and V the volume of the
reactor.
The continuous time representation of the bioreactor
system is:
dXdt
¼ � F
VX þ mðSÞX (1)
dS F
dt¼
VðSF � SÞ � sðSÞX (2)
where S is the substrate concentration and X is the cell
concentration. The growth model where all of the biomass
cells are ‘‘lumped together’’ in a single (one-hump) model
mðSÞ ¼ kSe�S=K (3)
is used to represent the substrate growth rate as a function of
biomass with K as the growth model coefficient. The specific
substrate consumption rate, s, is related to the yield coeffi-
cient Y in the form
YðSÞ ¼ mðSÞsðSÞ ¼ a þ bS (4)
where a and b are positive constants used to approximate the
increasing portion of the yield curve. Combining Eqs. (1)–
(4), the dimensionless cell and substrate mass balances can
be represented as
dC1
dt¼ �C1 þ Dað1 � C2Þec2=gC1 (5)
dC2 1 þ b c =g
dt¼ �C2 þ Da
1 þ b� C2ð1 � C2Þe 2 C1 (6)
where C1 and C2 are the dimensionless cell mass and
substrate conversion, respectively.
Brengel and Seider transformed Eqs. (5) and (6) to yield
the following system of equations incorporating the
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S. Ramaswamy et al. / Process Biochemistry 40 (2005) 2763–2770 2765
manipulated input variable, u which is the dimensionless
feed flow rate.
dX1
dtS
¼�ðC1S þ X1Þð1 þ uÞþ DaSð1� X2� C2SÞeðc2Sþx2Þ=g
� ðC1S þ X1Þ (7)
dX2 ðc2Sþx2Þ=g
dtS¼�ðC2S þ X2Þð1þ uÞ þDaSð1 �X2 �C2SÞe
� 1 þ b
1 þ b� X2 � C2SðC1S þ X1Þ (8)
where tS represents dimensionless time under steady state
conditions DaS, the Damkohler number at the steady state,
X1 the dimensionless cell mass deviation from steady state
and X2 is the corresponding dimensionless substrate con-
version deviation.
Fig. 2(a) is an open loop bifurcation diagram showing the
steady states and periodic branches over a range of values.
For low values of u, it can be seen that there are two steady
states, the upper state being stable while the lower one is
unstable. At u = 0.0778, the system undergoes a Hopf
bifurcation (i.e., limit cycle formation as a parameter is
varied [24]) resulting in three steady states, an upper repellor
encircled by a periodic attractor, a middle saddle and a lower
unstable state that becomes stable at the bifurcation point
u = 0.3023. An attractor is defined as some form of a long-
term recurrent behaviour that a dissipative dynamic system
will settle to [25]. By this definition, a periodic attractor is an
attractor that has a sin or cosin shape. Conversely, a repellor
is a solution that will go toward an unstable value [20,25].
Fig. 2. Open loop bifurcation diagram of (a) steady states and (b) substrate
conversions of the steady states.
Fig. 2(b) gives the substrate conversion for each of these
states. It was decided to use MPC to control the system to a
full repellor having values X1 = 0.05 and X2 = �0.078 at
u = 0.3846 with both eigenvalues 0.2126 � 2.0835i having
positive real parts. Analysis of the root locus (i.e., plot used
to represent the roots of the characteristic equation)
illustrates that conventional proportional-integral control
cannot be used to stabilize this unstable set point [26].
3. Model predictive control
Non-linear MPC is most naturally formulated in discrete
time and it becomes necessary to discretize the continuous
time differential equations. The discrete time representation
of the non-linear bioreactor model is given as
Xðk þ 1Þ ¼ f ½xðkÞ; uðkÞ; yðkÞ ¼ h½xðkÞ (9)
where x is an n-dimensional vector of state variables, u is an
m-dimensional vector of manipulated input variables, y is a
p-dimensional vector of controlled output variables, and f
and h are functions of x and U. The discretization was
performed using the Runge–Kutta four algorithm for numer-
ical integration [27]. In this case, X1 and X2 are the state
variables, the dimensionless flow rate is the input variable
and the output vector equals the state vector, i.e., x = y.
MPC is based on computing a set of M control moves that
minimize an objective function, based on a desired output
trajectory over a predictor horizon and implementing only
the first control move. This is schematically represented in
Fig. 3. The objective function normally is the sum of the
squares of the residuals between the model predicted outputs
and the set point values over the predictor horizon of P time
steps.
The MPC control algorithm is mathematically repre-
sented [28] as
minuðkjkÞ;uðkþ1jkÞ;...;uðkþM�1jkÞ
J
¼ f½yðk þ PjkÞ þXP�1
j¼0
L½yðk þ jjkÞ; uðk þ jjkÞ;Du
�ðk þ jjkÞ (10)
subject to certain process constraints where u(k + jjk) is the
input u(k + j) calculated from information available at time k,
y(k + jjk) is the output y(k + j) calculated from information
available at time k, Du(k + jjk = u(k + jjk) � u(k + j � 1jk),
M is the control horizon, P is the predictor horizon,f and L and
are non-linear functions of their arguments. It is meaningful to
consider quadratic functions of the form:
L ¼ ½yðk þ jjkÞ � ySðkÞTQ½yðk þ jjkÞ � ySðkÞ
þ ½uðk þ jÞ � uSðkÞTR½uðk þ jjkÞ � uSðkÞ
þ DuTðk þ jjkÞSDuðk þ jjkÞ (11)
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S. Ramaswamy et al. / Process Biochemistry 40 (2005) 2763–27702766
Fig. 3. Schematic representation of MPC control algorithm.
f ¼ ½yðk þ PjkÞ � ySðkÞTQ½yðk þ PjkÞ � ySðkÞ (12)
where uS(k) and yS(k) are steady state targets for u and y,
respectively and Q, R, and S are positive definite weighting
matrices. The controller tuning parameters are M, P, Q, R, S
and the sampling period Dt.
Based on a trial and error procedure, the predictor horizon
P was chosen to be 15 and the control horizon M was 1. The
sampling time Dt was 0.01 and the weights were Q = 10,
R = 0 and S = l. The process constraint was a lower bound of
�1 on the manipulated input u. A sequential solution
technique was used to implement the control algorithm
comprising of solution of the ordinary differential equations
as an inner loop to evaluate the objective function with an
optimization code as the outer loop.
Fig. 4(a)–(c) shows the time series response after
implementing MPC on the bioreactor from one initial
condition. It can be seen that the system has been
successfully controlled to the specified set point.
A number of tuning parameters such as control and
predictor horizons, weight matrices and sampling interval
affect controller performance and closed loop stability. In
this discussion, the effect of P on the stability of the closed
loop system was studied. For non-linear MPC, it is generally
known that predictor horizons shorter than a critical value
produce unstable control, typically oscillatory behaviour
[29]. In Fig. 5, we see this effect for predictor horizon values
less than 4. Small values of the predictor horizon greater
than the critical value result in less aggressive control
performance. Fig. 6 shows X1 versus u for one such predictor
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S. Ramaswamy et al. / Process Biochemistry 40 (2005) 2763–2770 2767
Fig. 4. Closed loop MPC response for (a) X1; (b) X2; and (c) u.
Fig. 5. Closed loop trajectory of the deviation of the dimensionless cell
mass from steady state, X1, using predictor horizon (P) = 3.
Fig. 6. Deviation of the dimensionless cell mass from steady state, X1, vs.
the manipulated input variable, u when the predictor horizon (P) = 5.
horizon, P. Values of between 10 and 20 gave excellent
controller performance (data not shown) and will not be
further discussed. However, for values of P greater than 20,
the controller performance degraded gradually with increas-
ing predictor horizons resulting in sluggish and oscillatory
responses until the closed loop system became unstable for
P = 149. Fig. 7 shows X2 versus X1 for P = 200. It can be
seen that the large value of the predictor horizon results in
the trajectory moving away from the steady state towards a
periodic attractor. Meadows and Rawlings [29] stated that
the effect of increasing predictor horizon diminishes as the
horizon becomes large, and the advantages of longer
horizons are outweighed by an increase in computational
time. However, we can see that for our system, large
predictor horizons result in loss of closed loop stability. The
loss of stability could be attributed to the fact that since the
operating point has both eigenvalues with positive real parts,
the effect of the repelling manifolds of the operating point
becomes significant when the values of P approach the time
constant of the open loop system. For bioreactor systems,
which normally have time constants that are substantially
larger than other chemical systems, the time constant of the
system becomes important in tuning the predictor horizon.
Increasing horizons result in Hopf-bifurcation-like closed
loop behaviour where a stable point becomes unstable
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S. Ramaswamy et al. / Process Biochemistry 40 (2005) 2763–27702768
Fig. 7. Predictor horizon causing trajectories to move toward a periodic
attractor. In this example, P = 200.
Fig. 9. Minimum values of u along closed loop basin of initial conditions in
X1 and X2.
creating stable limit cycles. An optimum value of P was
taken to be 15, as described earlier.
The MPC controller was tested on a basin of initial
conditions in order to analyze the effect of the changing
manipulated input flow rate on the system response. Fig. 8
shows the points in the basin that reach a lower bound on the
input u = �1 during the closed loop simulation. For these
initial conditions at u = �1, the MPC control algorithm
switches off the input to the reactor resulting in increasing
cell mass concentrations and substrate conversions while
u = �1, and the controlled system acts as an intermittent
batch reactor. Figs. 9 and 10 show a basin of feasible initial
conditions against the minimum and maximum values of the
manipulated input u along the closed loop trajectory. In
Fig. 10, it can be seen that the maximum u is very large for
certain initial conditions, the input flow rate increasing
significantly during the closed loop response, resulting in a
certain ‘washout’ condition. It can be inferred from these
figures that the controlled bioreactor is not directly driven to
Fig. 8. Basin of initial conditions that reach u = �l along a closed loop
trajectory.
the required set point. The non-linearities associated with the
system result in inefficient control causing batch or washout
conditions along the controlled system response. This is
confounded by the fact that most bioreactor, although
assumed to be homogeneous actually exhibit large inhomo-
geneities [3,30]. These results are also seen in plots of X1 and
X2 versus u for a number of initial conditions (Fig. 11(a)–(c)).
The results contained in Fig. 11 provide three key
findings. As shown in Fig. 11(a) with initial conditions low
in cell mass, the system acts like a batch reactor with the
controlled input turning off completely initially along the
closed loop trajectory. When the initial condition has high
cell mass and substrate conversion (Fig. 11(b)), the value of
the manipulated input becomes very large along the
trajectory resulting in ‘washout’ (i.e., completely opening
the valve). The washout occurs since the high conversion
rate results in low substrate concentrations that cannot
sustain the large cell mass. As depicted in Fig. 11(c), for
initial conditions that are high in cell mass but low in
Fig. 10. Maximum values of u along closed loop basin of initial conditions
in X1 and X2.
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S. Ramaswamy et al. / Process Biochemistry 40 (2005) 2763–2770 2769
Fig. 11. Effect of the manipulated input, u, on the dynamics of a controlled
system with (a) initial conditions low in cell mass; (b) initial conditions of
high cell mass and high substrate conversion; and (c) initial conditions of
high cell mass and low substrate conversion.
Fig. 12. Difference between the maximum and minimum values of u along
the closed loop trajectory for the basin of initial conditions in X1 and X2.
Trough depicts region of initial conditions that will result in stable control.
substrate conversion the value of the manipulated input
initially increases in order to sustain the high cell mass but
then decreases substantially. This considerable decrease is
due to the high concentrations of substrate already present,
that would be enough to sustain large cell concentrations.
Effective controllers requiring minimum input are
particularly advantageous for systems metabolite production
via microbes may be inhibited by catabolite repression or
inhibition from either the substrate or end product [31]. A
plot of difference in the maximum and minimum values of u
versus the initial conditions (Fig. 12) shows a certain trough-
like region where the input manipulation is minimum. The
initial conditions that lie in the trough exhibit minimum
change in input flow rate and hence provide the most
effective control. Thus, this analysis of the closed loop
trajectories clearly explains the relation between manipu-
lated input and the system behaviour for different conditions
and establishes regions for optimum controller performance.
4. Conclusions
In this paper, certain key issues for bioreactor control
have been addressed. It was shown that MPC could
successfully control a non-linear bioreactor to the unstable
operating point that resulted in optimal control of biomass
growth based on substrate concentration. This is a key
finding since very few biological systems are truly
homogenous or strictly first order. The effect of the
controller tuning parameter P on the stability of the
controlled system has been demonstrated. Values of P
between 15 and 20 yielded excellent control. When P > 20,
the controller performance degraded and generated an
oscillatory response. Analysis of the trajectories of the
controlled system generated a narrow operating region
(trough) for efficient control that required minimal
manipulation. It is important to note that even a well-
designed control scheme may result in poor control
performance causing batch or washout modes of operation.
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Appendix A. Nomenclature
a, b positive constants in approximated yield equation
C1 d
imensionless cell mass, X/(SFY(SF))C2 d
imensionless substrate conversion, (SF � S)/SFDa D
amkohler numberDaS D
amkohler number at steady statef f
unction of x and uF f
eed flow rateh f
unction of xJ o
bjective functionK m
aximum of one-hump growth modelL n
on-linear functionM c
ontrol horizonP p
redictor horizonS s
ubstrate concentrationt ti
meT s
ampling intervalu m
anipulated input variableV v
olume of bioreactorx s
tate variableX c
ell massX1 d
imensionless cell mass deviation from steady stateX2 d
imensionless substrate conversion deviation fromsteady state
y c
ontrolled output variableY y
ield coefficientGreek letters
b w
eighting coefficient a/(bSF)f n
on-linear functionk g
rowth model coefficientm s
pecific growth rates s
pecific substrate consumption ratet d
imensionless timeC w
eighting coefficient (K/SF)Subscripts
F f
eedS s
teady stateReferences
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