Washout-Filter-Based Stabilization Control for Continuous Ethanol Fermentation Under Delay-Induced Product Inhibition

Continuous ethanol fermentation is crucial for renewable bio-manufacturing, but delay-induced ethanol inhibition triggers self-oscillations via Hopf bifurcations, undermining productivity and stability. This study investigates instability mechanisms and proposes a washout-filter-aided control strategy. Using Hopf bifurcation theory, the critical delay time τc (20.97 h) was quantified, and it confirmed that τ > τc (intrinsic τ = 21.72 h) induces oscillations. Closed-loop analysis reveals that the filter extends τc to 25.57 h (e.g., K = 2, d = 0.5), expanding the stability margin by modulating ethanol dynamics through phase-shifted feedback. Numerical simulations and experimental validation demonstrate effective oscillation suppression, maintaining steady-state substrate (S* = 84.32 g/L), biomass (X* = 6.92 g/L), and ethanol (P* = 22.02 g/L) concentrations without sacrificing productivity. Unlike conventional methods, the strategy retains the system’s equilibrium structure, resists noise, and requires no additional hardware. This work bridges bifurcation analysis with practical control, offering a robust, scalable solution for industrial continuous ethanol production to mitigate delay-induced instabilities.