A New Concept for the Rapid Development of Digital Twin Core Models for Bioprocesses in Various Reactor Designs

In this research work, a new software tool concept and its application for the rapid and flexible development of mechanistic digital twin core models for bioprocesses in various reactor designs are presented. The newly developed software tool concept automatically combines user-selected submodels into an overall digital twin core model. The main part is a biokinetic submodel, of which three were designed for enzymatic, microbial and biocatalytic processes, which can be adapted to specific processes. Furthermore, the digital twin core model contains a physico-chemical submodel (e.g., calculating pH or oxygen transfer) and a reactor submodel. The basis of the reactor submodel is an ideally mixed stirred tank reactor. The biokinetic submodel is decoupled from the reactor submodels and enables an independent parameterisation of submodels. Connecting ideally mixed stirred tank reactor models allows for the simulation of different reactor designs. The implementation of an executable digital twin core model was accelerated, creating a new software tool concept. When the concept was applied, the development time and the computing time of digital twin core models for the cultivation of Saccharomyces cerevisiae in two coupled stirred tank reactors as well as for enzymatic hydrolysis processes in a packed-bed reactor were reduced by 90%.