Flow-following sensor devices: A tool for bridging data and model predictions in large-scale fermentations

Area of Science:

• Industrial Biotechnology
• Bioprocess Engineering
• Chemical Engineering

Background:

• Large-scale fermentation processes exhibit spatial gradients in critical parameters like dissolved gases, pH, and substrate concentrations.
• These gradients can negatively impact microbial production hosts, leading to reduced yields and profitability.
• Current methods struggle to obtain representative measurements across the entire reactor volume, hindering process optimization.

Purpose of the Study:

• To present the current state of flow-following sensor device technology.
• To explore the application of these sensors in large-scale bioreactors.
• To demonstrate how this technology can enhance process comprehension and validate computational models.

Main Methods:

• Review of state-of-the-art flow-following sensor devices.
• Discussion of advancements in microelectronics and sensor technology enabling these devices.
• Conceptual framework for deploying sensors in industrial bioreactors.

Main Results:

• Flow-following sensors are emerging as a viable technology for in-situ, multi-point measurements within bioreactors.
• Advancements in sensor technology facilitate the development of robust devices capable of operating in harsh fermentation environments.
• The integration of these sensors provides a pathway to bridge the gap between computational modeling and real-world process conditions.

Conclusions:

• Flow-following sensor devices hold significant potential for improving the understanding of heterogeneity in large-scale fermentation.
• This technology is crucial for validating computational fluid dynamics (CFD) models, thereby increasing their reliability.
• Successful implementation can lead to optimized bioprocesses, enhanced yields, and improved economic outcomes in industrial biotechnology.