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Significant energy savings can be made in aerobic stirred tank batch bioreactors by the manipulation of agitator power (Pag) and air flowrate per unit working volume (vvm). Control is often implemented to maintain the oxygen concentration in the bioreaction liquid (COL) at a constant value. This work used model simulations to show that controlling the Pag and vvm continuously over time, such that it is operated at or near the impeller flooding constraint results in the minimum energy requirement for oxygen transfer (strategy Cmin); however, this might prove impractical to control and operate in practice. As an alternative, the work shows that dividing the bioreaction time into a small number of constant Pag time segments (5–10), where a PID controller is used to control vvm to maintain COL constant in each segment, can achieve much of the energy saving that is associated with Cmin. During each time segment, vvm is increased and a sudden decrease in COL is used to detect the onset of flooding, after which there is a step increase in Pag. This sequence of Pag step increases continues until the bioreaction is completed. This practical control approach was shown to save most of the energy that is associated with Cmin.

Insights from Mathematical Modelling into Process Control of Oxygen Transfer in Batch Stirred Tank Bioreactors for Reducing Energy Requirement