New knowledge and skills requirements The introduction of these specialized chemical reactors necessitates process operators, technicians, and engineers to acquire a range of specialized competencies. These encompass an understanding of biology and microbiology, proficiency in aseptic techniques to ensure sterility, familiarity with bioreactor-specific instrumentation and control systems, knowledge of bioprocess engineering principles, and the ability to analyze and interpret data using analytical techniques. Increased complexity Standard reactors typically employ simpler control systems primarily geared toward ensuring the safety and basic stability of chemical reactions. In contrast, automation and control systems in bioreactors are notably more sophisticated and customized to meet the unique demands of biological processes. These systems prioritize the maintenance of precision and stability, with a strong emphasis on optimizing productivity through the application of advanced control strategies and data-driven decision-making. Typical field devices in bioreactors Various sensors and measurement devices monitor key parameters to ensure the proper functioning of the bioreactor and maintaining optimal conditions for the bioreaction. • Temperature sensors measure and maintain the temperature of the culture medium and provide feedback to the control system. • pH sensors continuously monitor the acidity or alkalinity of the culture medium, which can have a significant impact on cell growth and product formation. • Dissolved oxygen sensors measure the concentration of oxygen dissolved in the culture medium to ensure an adequate oxygen supply. • Pressure sensors ensure that the vessel operates within safe pressure limits and detect pressure fluctuations. • Level sensors monitor the liquid level in the bioreactor to ensure that the culture medium remains at the desired volume and prevent overflow or dry-out. • Biomass sensors measure the density or concentration of cells or microorganisms in the culture. • Gas sensors monitor the concentration of gases like oxygen, carbon dioxide, and other gases in the headspace or exhaust. • Conductivity sensors measure the electrical conductivity of the culture medium, which can be related to the concentration of ions and solutes in the medium. • Turbidity sensors measure the cloudiness or turbidity of the culture medium, which can indicate cell density or the presence of particles. • Redox potential (ORP) sensors measure the oxidation-reduction potential of the culture medium, an important parameter for some types of microbial processes. • Flow meters measure the flow rate of gases or liquids entering or exiting the bioreactor. They are important for controlling nutrient addition and waste removal. Essential input to the control systems Data is collected and processed by a data acquisition and control system (PLC, SCADA, DCS, or other) that allows workers to set and adjust parameters, receive real-time data, and make automated decisions to maintain optimal conditions, and troubleshoot any issues that may arise during the processes. Biologization Bioreactors Biologization harnesses the potential of biological processes and materials. As this trend continues to gain momentum, bioreactors are emerging as crucial enabling technologies in the process industry. They serve as essential tools for cultivating, controlling, and optimizing biological processes at a commercial and industrial scale. M32 Process automation I Learning solutions for education and training Magazine > Current trend topics
RkJQdWJsaXNoZXIy MzE0OTAwNw==