Operator training simulators for biorefineries: current position and future directions

TLDR

Advances in biofuel technology highlight a growing need for skilled biorefinery operators, yet existing operator training simulators from conventional chemical processes are limited by bioprocess‑specific challenges, prompting increasing interest in developing model‑based OTSs despite few large‑scale implementations. The review aims to assess current OTS development and usage in biorefineries and explore how such simulators can enhance operator competence, operational efficiency, and safety. The authors discuss the mathematical models underpinning OTSs, existing design frameworks and vendors, and evaluate their respective advantages and limitations. The review identifies future directions for OTS development and emphasizes their potential to accelerate the transition to a bio‑based economy. © 2018 Society of Chemical Industry.

Abstract

Abstract Recent technological advances in the development of alternative energy sources, including biofuels, for transportation and energy requirements have demonstrated the need for highly skilled engineers and operators in the biotechnological industries. Although operator training simulators (OTS) used in the traditional chemical process industries may be used to train biorefinery operators and engineers, several distinct aspects of bioprocess operations make their direct application limited. The development and deployment of OTSs for use in biotechnological processes is therefore beginning to gain increasing attention. This review paper examines the present status of OTS development and use in biorefineries, including future considerations on how an OTS may be used to improve operator competence, maximise biorefinery operational efficiencies and protect people and the environment. The general premise of an OTS is that model‐based operator training simulators can be used to verifiably enhance the training of industrial operators to run complex biorefineries. Only a few examples of the design and application of OTSs in large‐scale biorefineries have so far been reported. A discussion of the mathematical models used for OTS development is briefly presented, as well as available OTS design frameworks and vendors, including their benefits and drawbacks. The review concludes by looking at possible future directions of OTS development and use in biorefineries and their contribution in facilitating the transition to a bio‐based economy. © 2018 Society of Chemical Industry