Soft Sensor for Ethanol Fermentation Monitoring through Data-Driven Modeling and Synthetic Data Generation

This study presents a novel data-driven modeling approach employing machine learning to develop predictive “soft sensors” for real-time monitoring of ethanol and substrate levels during bioethanol fermentation processes. By utilizing readily measurable parameters such as pH, redox potential, capacitance, and temperature, the model enables continuous prediction of less frequently measured variables including ethanol, substrate, and cell concentrations. Eleven fermentations were conducted, focusing on intensified ethanol production from sugarcane substrate, utilizing cell cycling techniques to augment output. Despite the importance of fermentation data, its acquisition is often constrained by limitations in availability and resources. To address these challenges, this research integrates synthetic time series data generation, thereby enhancing the applicability of machine learning. Through the use of a variational autoencoder (VAE), synthetic time series data was successfully generated, facilitating training and testing of a deep neural network on both original and synthetic datasets. Results demonstrate a significant 30% increase in prediction robustness with the incorporation of generated data, while maintaining comparable accuracy levels. The augmented data effectively enhances the generalization ability of trained models, mitigating overfitting and expanding decision boundaries, thereby overcoming challenges associated with small datasets and inevitable data deviations. This innovative approach offers a promising avenue for enhancing the reliability and scalability of bioethanol fermentation monitoring through AI-based biosensors.