CFD‐based bioreactor model with proportional–integral–derivative controller functionality for dissolved oxygen and pH

Abstract A physics‐based model for predicting cell culture fluid properties inside a stirred tank bioreactor with embedded PID controller logic is presented. The model evokes a time‐accurate solution to the fluid velocity field and overall volumetric mass transfer coefficient, as well as the ongoing effects of interfacial mass transfer, species mixing, and aqueous chemical reactions. The modeled system also includes a direct coupling between process variables and system control variables via embedded controller logic. Satisfactory agreement is realized between the model prediction and measured bioreactor data in terms of the steady‐state operating conditions and the response to setpoint changes. Simulation runtimes are suitable for industrial research and design timescales.