Abstract: A method for on-line optimization of fed-batch fermentation unit containing bacteria and nutrients is disclosed. Parameters of the fermenter model used in optimization calculations are estimated periodically to reduce the mismatch between the plant and the calculated values. The updated fermenter model is used to calculate the optimum sugar feed rate to maximize the product yield. The method/fermenter model is implemented as a software program in a PC that can be interfaced to plant control systems for on-line deployment in an actual plant environment. An on-line optimization system is useful to the plant operating personnel, to maximize the product yield from the fed-batch fermenter unit. In another aspect, a plant control system to control a fed-batch fermentation based on the described method is also disclosed.

Abstract: A method is disclosed for on-line prediction of performance of a fermentation unit, such as prediction of performance parameters like concentration of product, biomass, or sugar in the broth of a batch/fed-batch fermentation unit containing bacteria and nutrients. A computer model predicts a future product concentration based on current plant data. While a batch is in progress, model parameters are adjusted on-line based on plant data to reduce a mismatch between the plant data and model data. A method/fermenter model can be implemented as a software program in a PC that can be interfaced to a plant control system for on-line deployment in an actual plant environment. An on-line performance monitoring system can be used by plant operating personnel, to know the performance of the batch in advance for implementing corrective measures in advance to improve/maintain performance at desired level.