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Ethanol Fermentation Suite — Simulator + Medium Calculator

Yeast Ethanol Performance Calculator + Time-Course Simulator

© 2026 FermAxiom LLC · Author: Peter Krasucki · peter.krasucki@fermaxiom.com  |  Anaerobic S. cerevisiae  |  Conceptual tool for rapid what-if analysis  |  v19.95

Instant rates + ODE simulation for Starch→Glucose→EtOH & Glycerol with strain presets (Ethanol Red, S288c, CEN.PK) and aeration regime.

Fermentation Conditions

Strain & operating conditions
Out of range (0–60°C)
Out of range (0–14)
Initial substrate concentrations
Must be ≥ 0
Must be ≥ 0
Must be ≥ 0
Enzyme dosing
Initial biomass & metabolites
Must be > 0
Gas-phase CO₂
Buffer system

Advanced Model Parameters

Growth kinetics
Must be > 0
Substrate model
Must be > 0
Must be > 0
Ethanol inhibition on growth
Must be > 0
Ethanol inhibition on production

Must be > 0
Temperature model

Must be < T_opt
Must be > T_opt
pH model
Must be < pH_opt
Must be > pH_opt
Yields & stoichiometry
Must be > 0
Must be > 0
Glycerol model
Cell death model

Must be ≥ 0
Enzyme inactivation model

Starch hydrolysis model

Must be > 0
Must be > 0
Must be > 0
Yeast on dextrins (MAL pathway)

Organic acid byproducts (pH effect)
Lactic and acetic acid are produced as minor byproducts during fermentation (or by contaminating bacteria). They accumulate in the broth and lower pH via their pKa equilibria (lactic pKa = 3.86, acetic pKa = 4.76). Set yields to 0 to disable.
Carbon balance check:

Fermentation Instant Predictions

Live state snapshot — derived from current input conditions

Sugar loaded
— g/L
St·1.11 + Dx·1.11 + S
Gay-Lussac ceiling
— g/L
sugar × 0.5114
Realistic max (95% GL)
— g/L
sugar × 0.485
Volumetric productivity
— g/L/h
rP at current state
Sugar consumption rate
— g/L/h
qS · X
Net growth rate (μ − kd)
— h⁻¹
+ = growing · − = dying
Doubling time
— h
ln 2 / μ_net
Apparent YP/S
— g/g
qP / qS
Glycerol fraction
— %
qGly·YS/Gly / qS
Limiting factor
growth bottleneck
Dominant glycerol driver
largest qGly contribution
Mass-balance status
ethanol / theoretical max
Growth & substrate uptake

Specific Growth Rate (μ)

0.000 h⁻¹
μ = μmax·fT·fpH·(S/(Ks+S))·fE·fS,inh

Specific Sugar Uptake (qS)

0.000 g/g/h
qS = μ/YX/S + mS·favail + qGly/YS/Gly
Ethanol production

Specific EtOH Rate (qP)

0.000 g/g/h
qP = YP/S·qS + α·μ + β

Volumetric EtOH Rate (rP)

0.000 g/L/h
rP = qP·X
CO₂ off-gas

Specific CO2 Rate (qCO₂)

0.000 g/g/h
qCO₂ = YCO₂/S·qS

Volumetric CO2 Rate (rCO₂)

0.000 g/L/h
rCO₂ = qCO₂·X
Glycerol production

Specific Glycerol Rate (qGly) — multi-factor breakdown

0.000 g/g/h
growth αGly·μ = 0.000   base qG0 = 0.000   osmotic = 0.000 (fosm=0.000)   ethanol = 0.000 (feth=0.000)   temperature = 0.000 (fT=0.000)   pH = 0.000 (fpH=0.000)   N-limit = 0.000 (1−fN=0.000)  
all g/g/h, then ×fs for sugar gating

Volumetric Glycerol Rate (rGly)

0.000 g/L/h
rGly = qGly·X
Starch hydrolysis & dextrins

Starch → Dextrins → Glucose

0.000 g/L/h
rhyd = (vliq+vGA·St)·YG/St · liquef. vliq=0, sacchar. vsac=0, GA-on-St vGA·St=0 g/L/h

Yeast on Dextrins (qDx)

0.000 g/g/h
MAL pathway uptake; glucose-repression factor fglu,rep=1.000 (1=fully derepressed, 0=fully repressed)
Cell viability & environment

Cell Death Rate (rd)

0.000 g/L/h
rd = kd,eff·X; kd,eff = kd·(1 + kd,E·E + kd,T·max(T−Topt,0)²)

pH (CO₂-corrected)

pH shift from dissolved CO₂ ⇌ H⁺ + HCO₃⁻ (pKa=6.35)

Health Check

Quick qualitative assessment of conditions.
Predictions charts (vs T & pH)
Active models driving these curves:

rP & YP/S,apparent vs Temperature

rP & YP/S,apparent vs pH

Active models driving these curves:

μ, μkd,eff, kd,eff vs Temperature

μ, μkd,eff, kd,eff vs pH

Active models driving these curves:

Glycerol decomposition: qGly,stress vs qGly,growthlike vs Temperature

Glycerol decomposition: qGly,stress vs qGly,growthlike vs pH

Model comparison tab — each chart overlays ALL available model options for one submodel, using the current strain/preset parameters. The curve corresponding to your currently selected model is drawn solid; alternatives are dashed for reference. Use this tab to preview what each selector in Advanced Model Parameters would do before you switch.

fT vs Temperature — Cardinal vs Gaussian

fpH vs pH — Cardinal vs Gaussian

fS vs Substrate — Haldane vs Monod × inhibition

fE vs Ethanol (growth) — Luong vs Hill vs Aiba

fE,p vs Ethanol (production) — Luong vs Hill vs Aiba

Cell-death kd,eff factors (v19.90) — thermal + pH decomposition

Time-Course Simulation (ODE)

Active model configuration — reflects current selections

Inoculum Sizing

Computed inoculum — from current targets and qP

Xavg required
— g DCW/L
= P / (qP · t)
Xpitch
— g DCW/L
= Xavg · ratio
Cell density
— × 10⁷ cells/mL
≈5×10⁷ cells/mL per g DCW/L
Wet yeast cream
— g/L broth
30% DCW basis

Nutrient Coupling & Environment

Nutrient status — Monod factors at current initial concentrations

FAN factor fN
N / (KN + N)
Mg factor fMg
Mg / (KMg + Mg)
Zn factor fZn
Zn / (KZn + Zn)
Sterol factor fErg
Ergq / (KErg + Ergq)
UFA/Tween factor fTw
Tw / (KTw + Tw)
Most limiting
smallest factor → Liebig
Typical ethanol ferm pH drops 0.5–1.0 units over a run due to ammonium assimilation releasing H+.
Time-course charts (Metabolism / Nutrients / Environment / Rates)
Limiting: —

Concentrations vs time

Theoretical vs actual ethanol yield

Gay-Lussac ceiling
Actual (simulated)

Yeast biomass & viability vs time

Yeast biomass summary & cell-count conversion

Pitch
Peak
End
Doublings
log₂(Xpeak/Xpitch)
Stationary onset
μ = kd,eff crossover
Viability (end)
Xend / Xpeak

Nutrients vs time

Nutrient consumption & limitation

Final broth nutrients
Cellular sterol quota

Environment vs time

Process environment summary

Temperature
pH
Peak [CO₂(aq)]
Enzyme activity

Rates vs time

Productivity & kinetics summary

Peak rP (ethanol rate)
Peak μ (growth rate)
Avg productivity
Peak death kd,eff

Time-Course Simulator — Quick Start

  1. Pick a strain preset in the Fermentation Conditions card → Strain & Regime sub-section (Ethanol Red for industrial fuel ethanol, S288c or CEN.PK for lab strains, or Custom). One click sets μmax, yields, ethanol tolerance, glycerol base rate, and starch-hydrolysis qDx,max in one go. The strain choice also primes the Advanced Model Parameters card with strain-specific defaults.
  2. The simulator auto-syncs from the Medium Calculator. Any change there — feedstock, titer, starch fraction, nutrients (FAN, Mg, Zn, ergosterol, oleate), yield sliders — propagates immediately into the Substrate, Init Conditions, and Nutrient Coupling sub-sections of the Fermentation Conditions card. The "← Import from Medium Calculator" button is still there as a manual refresh, but you shouldn't need it for routine edits.
  3. Verify Substrate Initial Conditions in the Substrate Pools sub-section. For starchy feedstocks (corn, wheat, cassava) you'll see low initial glucose [Glucose]Initial (2–10 g/L from the small free-sugar fraction in the grain) and high [Starch]Initial (150–260 g/L for VHG); enzymes hydrolyze starch to glucose during the run via the two-step pathway (Starch → Dextrins → Glucose). For pure sugars or molasses, all the sugar-eq lands as free glucose with 0 starch.
  4. Set Duration (h) in the Time-Course Simulation card — the single source of truth for fermentation time. The Inoculum Sizing card's "Target fermentation time" field is read-only and auto-mirrors Duration (⇄ badge), so Xavg = P / (qP·Duration) stays consistent.
  5. Tune Advanced Model Parameters if needed — the Advanced Model Parameters h2 expands into 11 sub-collapsibles (Substrate & Half-Saturations, Ethanol Inhibition (Cells), Ethanol Inhibition (Production), Temperature, pH Modulation, Yield Coefficients, Glycerol Multi-Factor, Cell Death, Enzyme Inactivation, Hydrolysis & Two-Step, MAL Pathway). Each opens to its own parameter group. Any change auto-triggers a re-run with a 180 ms debounce.
  6. Read the Live State Snapshot at the top of the Fermentation Instant Predictions card. Twelve cells show derived values from the current input state: Sugar loaded, Gay-Lussac ceiling, Realistic max (95% GL), Volumetric productivity (rP), Sugar consumption rate, Net growth rate (μ−kd), Doubling time, Apparent YP/S, Glycerol fraction, Limiting factor, Dominant glycerol driver, and a color-coded Mass-balance status (✓/~/○/✖). Useful as a sanity check before clicking Run.
  7. Explore the Fermentation Instant Predictions sub-collapsibles — Growth, Ethanol, CO₂, Glycerol, Stoichiometry, Viability, and Charts. The Charts sub-section opens 6 mini-charts (3 vs Temperature, 3 vs pH) at the current operating point:
    • Ethanol — rP (primary, blue/green) + rGly (secondary, purple dashed) on dual axes.
    • Yeast (growth/death) — μ specific growth rate (primary) + kd,eff effective death rate (secondary, red dashed). Crossover T marks washout.
    • Glycerol — rGly volumetric (primary, purple) + qGly specific (secondary, orange dashed). Diagnoses osmotic / redox stress.
  8. Click "Run simulation" (or rely on the auto-debounce). The Time-Course Simulation card's Charts sub-section shows glucose, starch, dextrins, ethanol, biomass, glycerol, and CO₂ evolving over Duration.
  9. Check the "Limiting" pill above the time-course chart tab bar — it reports which nutrient f-factor (Ergosterol, FAN, Mg, Zn, Tween-80, or "none") bottlenecks growth in the last third of the run.
  10. Inspect the Theoretical vs Actual Yield panel below the Metabolism chart — Gay-Lussac ceiling, actual simulated ethanol, efficiency tier (✓ excellent ≥88%, ~ typical 70–88%, ⚠ stuck <70%), and a stacked carbon breakdown bar (ethanol / residual sugar / biomass / glycerol / maintenance losses).
  11. Switch time-course chart tabs (Metabolism / Yeast / Nutrients / Environment / Rates) to diagnose what's happening at different stages of the run. Each tab now carries a computed summary panel beneath its chart in the same teal-accented style as the Live State Snapshot — Theoretical vs Actual yield for Metabolism, a 3×3 biomass/cells/cream grid for Yeast with DCW→cells conversion, a nutrient-consumption panel for Nutrients, a T/pH/CO2/enzyme panel for Environment, and peak-rates / average productivity / death-rate for Rates. Charts are 600 px tall with the container min-height locked so tab-switching never reflows the page, and the x-axis uses clean integer-hour ticks (1h / 2h / 6h / 24h step, auto-scaled to run duration).
  12. Highlight individual series or axis groups. Click any legend item to emphasise that curve (thick line; others dim to ~28% opacity); click again or click another item to switch. Click a Y-axis to highlight every series bound to that axis simultaneously — e.g., clicking the growth/death rate axis on the Yeast chart highlights μ, kd,eff, and μ−kd,eff together. The cursor changes to a pointer when hovering any Y-axis region. Pinned highlights persist through simulation re-runs.
  13. Optionally enable Volume tracking — in Fermentation Conditions → Strain & operating conditions, a dropdown offers three modes: Constant V (default, no change), Post-proc shrink from CO2 mass loss (ODE runs at constant V but display scales to Vfinal), and In-ODE rigorous (V integrated with the state vector; ethanol inhibition and Monod saturation feel the concentrating broth during the run). Typical VHG runs lose 5–10% volume to CO2 outgassing. The Theoretical vs Actual yield panel adds a V0→Vfinal line when tracking is on, and both the Gay-Lussac ceiling and the actual titer are then reported on the Vfinal basis (efficiency ratio stays invariant — it's a mass-conversion number).
  14. Iterate: if stuck, switch to the Medium Calculator tab and boost the limiting nutrient. Changes propagate back automatically; watch the efficiency climb. Export the CSV when satisfied.

Every section header in the Simulator (Fermentation Conditions · Inoculum Sizing · Nutrient Coupling · Fermentation Instant Predictions · Time-Course Simulation · Advanced Model Parameters) is click-to-collapse; Inoculum Sizing and Nutrient Coupling & Environment start collapsed by default so the left column reads as a compact table of contents. The same applies to the ~25 sub-collapsibles inside them — useful once you've configured a section. The cellular DCW-to-cell-count conversion factor is editable in Inoculum Sizing (default 5 × 1010 cells/g DCW ≈ 20 pg/cell for industrial S. cerevisiae; range 3–10 × 1010 covers strain and growth-phase variation). See the Model Notes → Science tab for the full mathematical definitions and References for primary sources.

Model Notes

Workflow guide and mathematical definitions for the combined suite

Combined workflow: Medium Calculator → Time-Course Simulator

The two tools are designed to work in sequence. Use the Medium Calculator first to specify what you are trying to produce, then watch the Simulator tell you whether the kinetics will actually deliver it within your time budget. Values flow automatically between the two — you can keep the Simulator open as a live monitor while you iterate on the recipe.

  1. Start in the Medium Calculator tab. The calculator is a design tool — it answers "what do I need to weigh out" given "what do I want to make". It's the canonical source of truth for the recipe.
  2. Enter your process targets: target ethanol production (L or US gallons), target titer (% v/v default 17 = VHG; also %w/v, g/L), and a feedstock from the 9-option dropdown. The feedstock's data attributes auto-fill Moisture % and Starch Fraction (the latter interpreted as % of sugar-eq from starch, not mass% of the feedstock — see bullet below). Override either if your raw material differs from the defaults.
  3. Click "Load Standard" in the Broth Target Concentrations card for fuel-ethanol-practice defaults on all 24 nutrient rows.
  4. Verify the recipe in the Summary card. The collapsible Summary card at the top of the right column shows three snapshot-style rows of computed values:
    • Production overview — Total Sugar Required (default kg, switchable to lbs / metric ton via the Units strip), Ethanol Produced (L abs. / US gal / kg / lbs), and Broth Volume (L / US gal / hL) with biomass-produced as the descriptor.
    • Substrate split (visible only when Starch Fraction > 0) — Starch Needed = starchFrac × sugar ÷ 1.11; Direct Glucose = (1 − starchFrac) × sugar; Feedstock (as-received) = dry mass ÷ (1 − moisture).
    • Enzyme loading (same trigger) — α-Amylase @ 500 U/g starch, Glucoamylase @ 200 U/g starch, plus the combined total. Auto-formatted as U / kU / MU.
    For glucose-only feedstocks (cane / beet molasses, pure sugars), the substrate + enzyme rows hide and a small italic notice replaces them. Mass balance bar (collapsible card below) should show 95–100% closure across Ethanol / CO₂ / Glycerol / Biomass / Other. Salt list lives in the Total Required tab inside Results & Tabs.
  5. Switch to the Time-Course Simulator tab. Initial glucose, starch, FAN, Mg, Zn, ergosterol, Tween-80, broth volume, and the target titer are already live-synced from the Medium Calc — no Import click needed for routine edits. (The green "← Import from Medium Calculator" button remains as a manual refresh.)
  6. Review the Fermentation Conditions card (collapsible via its ▼ header). Pick a strain preset (Ethanol Red for industrial, S288c/CEN.PK for lab, custom for bespoke calibration). For a starchy feedstock, verify Substrate [Glucose]Initial is low (typically 2–10 g/L) and Substrate [Starch]Initial is in the 150–260 g/L range — consistent with a VHG corn mash.
  7. Set Duration (h) in the Time-Course Simulation card. Duration is the single source of truth for fermentation time — the Inoculum Sizing card's "Target fermentation time" is read-only and auto-mirrors it (⇄ badge). Adjust expected qP (0.3–0.6 VHG, 0.8–1.2 normal, 1.5+ fast) and the card computes Xpitch = Xavg · ratio from P = qP·Xavg·Duration.
  8. Click "Run Simulation" or let the 180 ms auto-debounce re-run after any parameter change. The Metabolism chart shows glucose, starch, ethanol, biomass, glycerol, and CO₂ over Duration.
  9. Inspect the Theoretical vs Actual Yield panel — ✓ excellent ≥88%, ~ typical 70–88%, ⚠ stuck <70%. The stacked carbon bar shows where missing yield went (residual sugar, biomass, glycerol, maintenance / death losses). If the Volume tracking mode (Fermentation Conditions → Strain & operating conditions) is set to anything other than Constant V, the panel adds a V0→Vfinal line reflecting broth shrink from CO2 outgassing, and both ceiling and actual titer are expressed on the Vfinal basis so they are directly comparable.
  10. Switch time-course chart tabs — five tabs (Metabolism / Yeast / Nutrients / Environment / Rates) each carry a dedicated summary panel beneath the chart. The Yeast tab includes biomass in both g DCW/L and cells/mL, with the DCW→cells conversion factor user-editable in the Inoculum Sizing card (default 5 × 1010 cells/g). Click a legend item to isolate one series or a Y-axis to highlight every series bound to that axis.
  11. Explore the Instant Predictions tabs (right column) to understand how rates depend on T and pH at your current operating point:
    • Ethanol Product — rP + rGly dual-axis vs T and pH.
    • Yeast Product — μ + kd,eff dual-axis. Crossover point = washout limit.
    • Glycerol Product — rGly volumetric + qGly specific. Osmotic / redox stress diagnostic.
  12. Check the "Limiting" pill above the time-course charts. If "Ergosterol" → raise broth ergosterol in the Medium Calc. If "FAN" → more DAP or yeast extract. If "none" → the shortfall is kinetic, not nutrient-limited.
  13. Iterate. Go back to the Medium Calculator, adjust. Changes propagate back automatically; watch the simulator re-run and verify the efficiency climbs. Export the CSV when you're happy and plan your bench-scale validation.
  14. Calibrate with real data (Model Exp. Data tab). Once you have laboratory HPLC time-course data from a bench or pilot fermentation, switch to the Model Exp. Data tab. Upload your CSV/TSV file (or paste directly), then follow the calibration workflow: Statistical analysis to check data quality and identify what parameters the data supports estimating → Calculate parameters to get analytical first-pass estimates from the data → Apply to simulatorEvaluate fit to see R²/RMSE/bias per species → Train (optimise) to iteratively refine remaining parameters. The fitted model can then predict scale-up scenarios with strain-specific confidence.
  15. Read the Science sub-tab for the mathematical definitions.

Why this order matters: the Medium Calculator is the canonical source of truth for the recipe. It has no opinion about kinetics (it doesn't know about μmax, Emax, ergosterol dilution, or cell death), but it guarantees the mass balance. The Simulator is the kinetic check that tells you whether a mass-balanced recipe will actually ferment to completion within your target time. Using the calculator first means you never simulate a recipe that can't possibly work on paper; using the simulator second means you catch the kinetic failures (stuck fermentation, ethanol toxicity, ergosterol dilution) that pure mass balance misses. And because Medium Calc → Simulator is auto-wired, you can edit either view and see the consequence immediately in the other.

Equations and assumptions

  • Temperature factor (cells): Two models, user-selectable. Cardinal (default, Rosso, Lobry & Flandrois 1993, CTMI): fT = (T−Tmax)(T−Tmin)² / [(Topt−Tmin) · ((Topt−Tmin)(T−Topt) − (Topt−Tmax)(Topt+Tmin−2T))] for Tmin < T < Tmax, and exactly 0 outside that interval. Asymmetric (long shoulder below Topt, sharp drop above), with biologically interpretable cardinal temperatures (defaults Tmin=5°C, Topt=32°C, Tmax=42°C for industrial S. cerevisiae). Gaussian (legacy): fT = exp(−((T−Topt)²/(2σT²))) — symmetric, never reaches zero. Useful for back-compatibility with older parameter sets.
  • pH factor (cells): Two models, user-selectable. Cardinal pH Model (default, Rosso et al. 1995): fpH = (pH−pHmax)(pH−pHmin)² / [(pHopt−pHmin) · ((pHopt−pHmin)(pH−pHopt) − (pHopt−pHmax)(pHopt+pHmin−2pH))] — asymmetric (long acidic shoulder, sharp alkaline cliff), reflecting S. cerevisiae's real pH response. Gaussian (legacy): fpH = exp(−((pH−pHopt)²/(2σpH²))).
  • Substrate kinetics (cells): Two models, user-selectable. Haldane (default, unified): muS = S / (Ks + S + S²/Ki,S). Combines Monod uptake and substrate-inhibition into one biologically-grounded expression. Monod × inhibition (legacy): Monod S/(Ks+S) multiplied by 1/(1 + S/Ki,S).
  • Ethanol inhibition (cells): Three models, user-selectable. Luong (default, 1985): fE = 1 below Einh, ((Emax−E)/(Emax−Einh))n in the inhibition range, 0 above Emax. Best empirical fit for S. cerevisiae. Hill (legacy): fE = max(0, (1 − (max(E−Einh,0))/Emax)n). Aiba (1968): fE = exp(−kE · E). Smooth exponential; never reaches zero.
  • Ethanol inhibition (production, decoupled): Same three model choices, separate parameters (Emax,p, Einh,p, np, kE,p). Only the Luedeking-Piret β term is gated by fE,p — this is the *specifically* ethanol-inhibited non-growth production contribution. Maintenance catabolism (mS, regime-adjusted ~25× higher for anaerobic than aerobic) continues regardless of E, because live cells always need ATP for maintenance. What actually terminates fermentation is cell death (kd,eff rising with E), which drives X → 0 and thus rP = qP·X → 0 — not a hard metabolic cliff.
  • Smooth substrate depletion: A soft-switch factor favail = S/(S + Ks,min) (Ks,min = 0.01 g/L) replaces the hard S=0 cutoff, ensuring rates taper smoothly as substrate runs out rather than dropping discontinuously.
  • Substrate consumption: qS = μ/YX/S + mS·favail + qGly/YS/Gly; maintenance scales with substrate availability.
  • Cell death (v19.90): kd,eff = kd·(1 + kd,E·E + kd,T·[(T−Toptheat + fcold·(T−Toptcold] + kd,pH·(pH−pHopt)²). dX/dt = (μ − kd,eff) · X. Heat-stress (T > Topt) drives most thermal death; cold-stress contributes a tunable fraction fcold (default 0.3) of the same quadratic to reflect membrane/osmotic damage at low T. The pH term was added to capture real yeast mortality at extremes of acidity or alkalinity (default kd,pH=0.05 per pH-unit²).
  • Enzyme hydrolysis (starch→glucose): vhyd = khyd·(Eeff·1000)·fact·fT,E·fpH,E·(Starch/(Km,starch+Starch)); where Eeff = GA + 0.25·AA (U/mL); fact is the remaining active fraction (decays via first-order inactivation).
  • Enzyme thermal inactivation: dfact/dt = −kinact · Q10(T−Tref)/10 · fact. Activity decays faster at higher temperatures (Q10 = 2).
  • Instant rates (cells): qS = μ/YX/S + mS·favail + qGly/YS/Gly, qP = YP/S·qS + α·μ + β; rP=qP·X; qGly = αGly·μ + qG0·stress(E,S,pH).
  • ODEs: dStarch/dt = −vhyd; dS/dt = rhyd − qS·X; dX/dt=(μ − kd,eff)·X; dEtOH/dt=qP·X; dGly/dt=qGly·X; dCO2/dt = qCO₂·X; dfact/dt = −kinact,eff·fact; dLA/dt = YLA/S·qS·X; dAA/dt = YAA/S·qS·X. 15 state variables, integrated with RK4.
  • Mass balance check: Carbon in (glucose consumed + starch consumed) vs carbon out (ethanol + CO2 + glycerol + biomass). Warns if balance deviates >5%.
  • Feedstock mass balance (Medium Calculator): Total fermentable sugar required is computed as sugar = ethG / YE/S, then split between two paths. Dry feedstock needed = sugar / Ysugar/feedstock, where Y depends on the selected raw material: 1.00 g/g for pure glucose/sucrose, 1.10 for purified starch (stoichiometric hydrolysis), 0.80 for whole-kernel corn (~70% starch × 1.11 + ~3% free sugar), 0.83 for degermed corn flour, 0.81 for whole-grain corn meal, 0.78 for wheat flour, 0.70 for barley malt, 0.88 for dry cassava, 0.50 for cane molasses, 0.48 for beet molasses. As-received (wet) mass = dry mass ÷ (1 − moisture_fraction), so at 14% moisture, 20 kg dry corn weighs 23.3 kg as received. The feedstock dropdown pre-fills typical moisture values (grains 12–14%, molasses ~20%, purified starch ~11%, pure sugars 0%) and a Starch Fraction expressed as % of sugar-eq from starch hydrolysis, not mass%. Defaults: 100 for purified starch, 97 for whole corn, 98 for corn flour, 96 for corn meal, 97 for wheat, 87 for barley malt (malting pre-converts some starch to free sugars), 99 for cassava, 0 for pure sugars and molasses. The Starch Fraction drives the initial-condition split: at t=0 the broth contains (1 − starchFrac) × sugar-eq as free glucose and (starchFrac × sugar-eq) ÷ 1.11 as solid starch; amylase enzymes (α-amylase 500 U/g starch, glucoamylase 200 U/g starch) hydrolyze the starch to glucose during fermentation.
  • Instant-Predictions dual-axis charts: three tab groups in the right column of the Simulator sample rates across temperature (0–50 °C) and pH (2–8) at the current operating point, each with two series on a primary/secondary y-axis. Ethanol Product: rP primary + rGly secondary (both volumetric, g/L/h). Yeast Product: μ primary + kd,eff secondary (both specific, h⁻¹); crossover point = washout T. Glycerol Product: rGly primary (volumetric, g/L/h) + qGly secondary (specific, g/g/h), useful for osmotic / redox stress diagnosis. All three tabs re-render on every parameter change via the 180 ms debounce.
  • Nutrient coupling (Phase 2): μ is multiplied by a Liebig's-minimum factor fnutrients = min(fN, fMg, fZn, fErg, fTween), where each f is a Monod term on the corresponding nutrient. Growth slows sharply when any one nutrient falls below its half-saturation constant. The dominant limiter is reported in the "Limiting" pill above the time-course charts.
  • FAN depletion: dN/dt = −(μ/YX/N)·X. With YX/N ≈ 10 g DCW/g N, 700 mg/L FAN supports ~7 g/L biomass growth — the boundary between normal-gravity and VHG fermentation.
  • Cellular ergosterol dilution: d(Ergq)/dt = −μ · Ergq. Pure dilution — anaerobic yeast cannot synthesize sterols. The initial quota is erg_q_init + erg_init_broth / X0, so increasing either the per-cell reserve or the broth supplement shifts stuck-fermentation onset. This is the mechanism behind VHG stuck fermentations at 40–60% sugar utilisation.
  • Adiabatic heat balance (optional): When temperature mode = adiabatic, T becomes a state variable with dT/dt = (Qmetab − Qcool)/Cp, where Qmetab = rP·ΔHferm/MEtOH and Qcool = kcool·(T − Tset). Drop kcool to see runaway heating.
  • pH drift from NH4+ assimilation (Phase 3): Each mole of ammonium taken up releases 1 mole of H+ as neutral N is incorporated into biomass. Modeled as a strong acid (pKa = −2) with cumulative concentration (Ninit − Nbroth) · hper_N / MN, added to the existing aqueous-chemistry buffer solver. hper_N is tunable (0 for urea-only, 1 for pure NH4+, 0.5 for typical FAN mixtures).
  • Inoculum sizing engineering identity (Phase 3): P = qP·Xavg·t, so Xavg = P / (qP·t). The sizing card solves this for target ethanol titer (auto-synced from Medium Calc) and fermentation time (read-only field auto-mirrored from Duration — the single source of truth for time), then converts Xavg → Xpitch via a tuneable ratio (default 0.6 for mild growth during lag + exponential phase).
  • Live coupling to Medium Calculator: calc() in the Medium Calc updates window._calcCanonical with the unit-resolved totals (sugarG, ethVolL, volumeL, biomassG) on every input change, then calls importFromMedium() which reads those canonical values and pushes them into the Simulator's Fermentation Conditions (s, st) and Nutrient Coupling (n_init, mg_init, zn_init, erg_init_broth, tween80_init) fields — plus syncTiterToInoculum() for the Inoculum Sizing card. A recursion guard prevents re-entry. The green "← Import from Medium Calculator" button remains as a manual refresh escape hatch.
  • Regime multipliers are applied relative to the strain-preset base values and are indicative only; they do not compound on repeated changes. Calibrate with your own strain data.
  • Environmental viability gate (v19.90): both the maintenance term and the non-growth-associated Luedeking–Piret production are now multiplied by fenv = fT·fpH. At cardinal-model extremes where fT=0 or fpH=0, mS·fS·fE,p·fenv = 0 and β·fE,p·fenv = 0, i.e. dormant cells don't consume sugar for maintenance or produce ethanol non-growth-associatedly. Previously a ~0.5 g/L/h floor persisted at T=0 or pH=2 (physically impossible). The fix makes the rP vs T / pH charts drop cleanly to zero outside [Tmin, Tmax] and [pHmin, pHmax].
  • VHG glycerol coupling (v19.90): the growth-coupled glycerol term is now qg,growth = αGly·μ·(1 + kVHG,Gly·fosm), coupling αGly to the same osmotic Hill that drives qg,osm. This reflects biochemistry: under high total osmolyte, NADH disposal during biosynthesis becomes more glycerol-intensive because the cell is already stressed. At kVHG,Gly=1 (default), full VHG (fosm→1) doubles αGly. Setting kVHG,Gly=0 recovers the pre-v19.90 behaviour. qgly is now decomposed into qgly,stress (osm+eth+T+pH+N, U-shape in T/pH) and qgly,growthlike (α·μ·(1+kVHG·fosm) + qG0, Gaussian) so the two biochemically distinct mechanisms display as separate curves on the Glycerol Product instant chart.
  • Instant-prediction chart semantics (v19.90): the three prediction tabs were rebuilt to show distinct information instead of three copies of the μ-Gaussian. Ethanol Product now shows rP primary + YP/S,apparent = qP/qS secondary (the effective yield after maintenance and glycerol diversions). Yeast Product now shows μ primary, μ−kd,eff (net growth, dashed purple), and kd,eff (dotted red, right axis) — the zero-crossings of the net curve mark the WASHOUT boundaries. Glycerol Product plots the two decomposition buckets described above.
  • Organic acid production & dynamic pH coupling (v19.95): Lactic acid (LA) and acetic acid (AA) are now dynamic ODE state variables: dLA/dt = YLA/S·qS·X, dAA/dt = YAA/S·qS·X, with production yields defaulting to 0 (no production unless user enables or optimizer fits). Both accumulate during fermentation and feed back into the pH calculation via their pKa equilibria (lactic pKa = 3.86, acetic pKa = 4.76) through the buildDynamicAcids() function, which replaces the static initial organic acid concentrations in the pH solver at each RK4 timestep. The full pH model now includes four acid sources: CO2 dissolution (H2CO3), NH4+ assimilation H+ release, dynamic lactic acid, and dynamic acetic acid — all solved simultaneously in the bisection-based proton balance. Environment chart shows both species on a dedicated "Org. acids (g/L)" axis.
  • Model Exp. Data tab (v19.95): Fourth main tab for fitting the model to observed fermentation data. Accepts all 12 standard ethanol fermentation HPLC columns: time, pH, temperature, DCW, DP4+, DP3, DP2, DP1, lactic acid, glycerol, acetic acid, ethanol. Column names are case-insensitive with multiple aliases supported (e.g. ethanol, EtOH, E all match). DP2 + DP3 are automatically summed to a dextrin pool for scoring against the model's dextrin trajectory. Replicate samples at the same time point are automatically detected and averaged to mean ± SD.
  • Model Exp. Data — four actions (v19.95):
    • Statistical analysis — evaluates raw data quality: dataset overview (time points, duration, sampling density), per-species quality table (n valid, missing, min/max/range, CV% from replicates, trend detection ↑↓→↕, quality rating ✅⚠️❌), parameter estimability checklist (which parameters the data can support estimating), and data limitation warnings (too few points, missing species, no replicates, large gaps, short duration).
    • Evaluate fit — runs the simulator with current parameters, interpolates predictions at observation times, and reports R², RMSE, and mean bias per species. Overlays observed data as scatter points on the Metabolism chart.
    • Calculate parameters — derives kinetic parameters analytically from the time-course data: μmax (corrected: slope of ln(X) + kd,eff ÷ fproduct at operating conditions), YX/S (apparent ΔX/ΔS), YP/S (apparent ΔE/ΔS), α/β (Luedeking–Piret regression of qP vs μ), kd (apparent kd,eff from decline phase), mS (apparent stationary-phase qS), plus glycerol and organic acid yields. All parameters labeled "apparent" with explanations of entanglement with the full ODE model.
    • Train (optimise) — Nelder–Mead simplex on user-selected parameters, normalised [0,1] within bounds, async with Stop button. 14 fittable parameters across 3 groups: growth kinetics (μmax, KS, mS, kd, kd,E), yields (YX/S, YP/S, αGly, YLA/S, YAA/S), ethanol production (α, β, Emax, Einh).
    A "Next steps" panel appears after each action with contextual guidance and re-run buttons for iterative refinement.
  • Broth volume tracking from CO2 outgassing: ethanol fermentation loses mass as C6H12O6 → 2 C2H5OH + 2 CO2 drives 0.4886 g of CO2 out of each gram of glucose consumed. On typical VHG mashes, 5–10% of broth volume exits as gas. Three modes are available (Fermentation Conditions → Strain & operating conditions → Volume tracking): Constant V (default, no tracking); Post-proc — ODE runs at constant V, then Vfinal is computed from cumulative CO2 mass balance and all in-solution species are rescaled by V0/Vfinal for display; In-ODE rigorous — V becomes a state variable (15-element vector: st, s, x, e, gly, co2_aq, f_act, N, Mg, Erg_q, T, dx, V, la, aa) with dV/dt = −rCO2·V/(ρ·1000); the companion dilution term +C·rCO2/(ρ·1000) is applied to every per-broth-volume species (starch, glucose, biomass, ethanol, glycerol, dissolved CO2, FAN, Mg, dextrins, lactic acid, acetic acid), derived from the product-rule expansion d(C·V)/dt = r·V. Ergq (per-biomass mg/g DCW), fact (dimensionless), and T (intensive) do not receive the dilution term. In-ODE mode captures the nonlinear coupling where ethanol inhibition feels the rising concentration during the run — slightly lowering total ethanol mass but raising end-of-run g/L.
  • DCW → cell count conversion: cells/mL = X (g DCW/L) × fcells × 107, where fcells is a user-editable input in the Inoculum Sizing card (field: "Cells per g DCW", units ×1010). Default 5 corresponds to ~20 pg single-cell dry weight (industrial S. cerevisiae exponential phase). Published values span 3–10 (60–200 pg/cell equivalent) depending on strain, growth phase (stationary cells carry glycogen/trehalose → heavier), ethanol stress (cells shrink in VHG runs), and measurement method. The factor is used by the Inoculum Sizing cell-density readout, the Yeast chart's cells-per-mL curve, and the Yeast summary panel's Pitch/Peak/End cell counts.

Strain presets are indicative; calibrate with your strain data. Regime modifies yields and glycerol base to mimic redox shifts.

References

Key primary sources for the kinetic, stoichiometric, and engineering choices encoded in the suite. All citations are illustrative — the implementation often blends or adapts published forms; see the bullets above for exact functional forms.

  • Luedeking, R. & Piret, E. L. (1959). A kinetic study of the lactic acid fermentation. J. Biochem. Microbiol. Technol. Eng. 1: 393–412. — Original growth-associated + non-growth product term qP = α·μ + β.
  • Luong, J. H. T. (1985). Kinetics of ethanol inhibition in alcohol fermentation. Biotechnol. Bioeng. 27: 280–285. — fE with Einh threshold and Emax; default ethanol-inhibition model in this suite.
  • Aiba, S., Shoda, M. & Nagatani, M. (1968). Kinetics of product inhibition in alcohol fermentation. Biotechnol. Bioeng. 10: 845–864. — Exponential fE = exp(−kE·E); legacy alternative.
  • Andrews, J. F. (1968). A mathematical model for the continuous culture of microorganisms utilizing inhibitory substrates. Biotechnol. Bioeng. 10: 707–723. — Haldane substrate-inhibition term S/(Ks+S+S²/Ki,S).
  • Bai, F. W., Anderson, W. A. & Moo-Young, M. (2008). Ethanol fermentation technologies from sugar and starch feedstocks. Biotechnol. Adv. 26: 89–105. — VHG fermentation, industrial yield benchmarks (YE/S=0.45–0.49), feedstock yield coefficients.
  • Walker, G. M. (2011). Pichia and Saccharomyces yeast biology. The Yeasts: A Taxonomic Study, 5th ed. — Magnesium / zinc / vitamin requirements, sterol & unsaturated-fatty-acid auxotrophy under anaerobiosis.
  • Casey, G. P. & Ingledew, W. M. (1986). Ethanol tolerance in yeasts. CRC Crit. Rev. Microbiol. 13: 219–280. — Membrane / Mg²⁺ / lipid mechanisms behind ethanol toxicity; basis for VHG sterol & oleate supplementation.
  • Pham, T. K. & Wright, P. C. (2008). The proteomic response of Saccharomyces cerevisiae in very high glucose conditions. J. Proteome Res. 7: 4766–4774. — Osmotic-stress glycerol overproduction; basis for the Hill term qg,osm.
  • Atala, D. I. P., Costa, A. C., Maciel, R. & Maciel Filho, R. (2001). Kinetics of ethanol fermentation with high biomass concentration. Appl. Biochem. Biotechnol. 91–93: 353–365. — Cell-death rate dependence on ethanol & temperature.
  • Verduyn, C. et al. (1990). Physiology of Saccharomyces cerevisiae in anaerobic glucose-limited chemostat cultures. J. Gen. Microbiol. 136: 395–403. — Anaerobic YX/S ≈ 0.10 g/g, ergosterol & UFA quotas, maintenance coefficient mS.
  • Cot, M., Loret, M.-O., François, J. & Benbadis, L. (2007). Physiological behaviour of Saccharomyces cerevisiae in aerated fed-batch fermentation for high-level production of bioethanol. FEMS Yeast Res. 7: 22–32. — Industrial fed-batch & ergosterol dilution behaviour.
  • Stewart, G. G. (2017). Brewing and Distilling Yeasts. Springer. — α-Amylase / glucoamylase loading conventions (≈500 U/g starch / 200 U/g starch), nitrogen targets (200–700 mg FAN/L for normal-gravity to VHG).
  • Pirt, S. J. (1965). The maintenance energy of bacteria in growing cultures. Proc. R. Soc. B 163: 224–231. — Maintenance-energy framework underpinning the mS·X term.
  • Kosaric, N. & Vardar-Sukan, F. (2001). Potential source of energy and chemical products. In The Biotechnology of Ethanol, Wiley-VCH. — Feedstock-yield reference values for corn / wheat / cassava / molasses.

Ethanol Fermentation Medium Calculator

© 2026 FermAxiom LLC · Author: Peter Krasucki · peter.krasucki@fermaxiom.com  |  Anaerobic S. cerevisiae  |  Conceptual tool for rapid what-if analysis  |  v19.95

Batch + VHG Fed-Batch  •  Broth-Concentration Driven  •  Real-time

Target Production
Ethanol Fermentation Targets
Feedstock & Substrate
% of sugar-eq
At t=0 the broth contains (1 − starchFrac) × sugar-eq as free glucose and (starchFrac × sugar-eq) ÷ 1.11 as solid starch; enzymes hydrolyze the starch to glucose during fermentation. Amylase enzymes (α-amylase 500 U/g starch, glucoamylase 200 U/g starch) are added automatically when starch > 0.
0.80 g/g
Fermentable sugar yield per g dry feedstock. Selecting a feedstock auto-populates moisture % and starch % below.
% w/w
Grains 12–14% · molasses ~20% · pure sugars 0%. As-received mass = dry mass ÷ (1 − moisture/100).
When enabled, the salt recipe is reduced by the nutrients the raw feedstock itself delivers (FAN from protein, K/Mg/P from ash, B-vitamins, etc.). Default OFF — salt masses assume a synthetic-glucose baseline. Credits are based on typical literature values; for scaled-up work, assay your feedstock lot.
Stoichiometric Yields & Batch %
Ethanol Yield on Sugar (YE/S) 0.46 g/g
Biomass Yield on Sugar (YX/S) 0.050 g/g
Glycerol Yield on Sugar (YGly/S) 0.040 g/g
% Nutrients in Initial Batch Phase 100%
Broth Volume 82.9 L
Initial Sugar 206 g/L
Biomass Produced 857 g
CO₂ Evolved 7.56 kg
Feedstock Required (as-received) — kg
Broth Target Concentrations (editable · mg / L)
Macronutrients 7 entries
Element / Factor Min. Max. Target Unit
Nitrogen (as FAN) 200 700 mg/L
Phosphorus (P) 150 400 mg/L
Potassium (K) 300 800 mg/L
Magnesium (Mg) 50 250 mg/L
Sulfur (S) 100 300 mg/L
Calcium (Ca) 20 100 mg/L
Sodium (Na) 500 mg/L
Trace Metals 6 entries
Element / Factor Min. Max. Target Unit
Iron (Fe) 2 30 mg/L
Zinc (Zn) 0.5 5 mg/L
Manganese (Mn) 0.2 2 mg/L
Copper (Cu) 0.05 0.5 mg/L
Molybdenum (Mo) 0.02 0.2 mg/L
Cobalt (Co) 0.02 0.2 mg/L
Vitamins 8 entries
Element / Factor Min. Max. Target Unit
Biotin (B8) 0.05 0.3 mg/L
Thiamine (B1) 1 10 mg/L
Riboflavin (B2) 0.5 2 mg/L
Nicotinic A. (B3) 2 10 mg/L
Pantothenate (B5) 2 10 mg/L
Pyridoxine (B6) 0.5 2 mg/L
Folic A. (B9) 0.1 0.5 mg/L
Inositol 10 50 mg/L
Anaerobic Lipid Factors · essential under anaerobiosis 2 entries
Element / Factor Min. Max. Target Unit
Ergosterol 5 20 mg/L
Tween-80 (oleate src) 100 1000 mg/L
Summary

Fermentation summary — computed from current targets

Total Sugar Required
17.15 kg
ethanol ÷ YE/S
Ethanol Produced
10.0 L
absolute ethanol at target titer
Broth Volume
82.9 L
biomass produced
Starch Needed
— kg
starchFrac × sugar ÷ 1.11
Direct Glucose
— kg
(1 − starchFrac) × sugar
Feedstock (as-received)
— kg
dry mass ÷ (1 − moisture)
α-Amylase
— kU
@ 500 U/g starch (liquefaction)
Glucoamylase
— kU
@ 200 U/g starch (saccharification)
Total Enzyme Load
— kU
α-amylase + glucoamylase
Units:
Carbon Mass Balance
Results & Tabs
Total Required  ·  grouped by category  ·  click any header to expand/collapse
Macronutrients
CompoundSalt / NoteTotal RequiredUnit
Trace Metals
CompoundSalt / NoteTotal RequiredUnit
Vitamins
CompoundSalt / NoteTotal RequiredUnit
Anaerobic Lipid Factors · essential under anaerobiosis
CompoundSalt / NoteTotal RequiredUnit
Initial Batch Medium  ·  All nutrients added at t = 0  ·  click headers to expand/collapse
Macronutrients
CompoundTotal in Batch (g)Concentration (g/L)
Trace Metals
CompoundTotal in Batch (g)Concentration (g/L)
Vitamins
CompoundTotal in Batch (g)Concentration (g/L)
Anaerobic Lipid Factors · essential under anaerobiosis
CompoundTotal in Batch (g)Concentration (g/L)
VHG Fed-Batch Feed  ·  Added during fermentation (only if batch % < 100)  ·  click headers to expand/collapse
Macronutrients
CompoundTotal to Feed (g)Unit
Trace Metals
CompoundTotal to Feed (g)Unit
Vitamins
CompoundTotal to Feed (g)Unit
Anaerobic Lipid Factors · essential under anaerobiosis
CompoundTotal to Feed (g)Unit

Ethanol Fermentation — Recommended Broth Concentrations

Targets reflect typical fuel-ethanol practice and literature guidance (Ingledew, Bafrncová, Jones & Pierce, Casey & Ingledew). Unlike propagation, these are broth concentrations, not per-kg-biomass. Defined-medium work; molasses/mash already supplies much of this.
Click any header to expand/collapse.

Macronutrients 7 entries
Element /
Factor
Typical
target
Min.Max.UnitNotes
Nitrogen (as FAN)700200700mg/LFree amino nitrogen — 200–300 adequate for 12% v/v; 400–500 for 15%; 500–700 for VHG (>17% v/v). Deficiency causes sluggish fermentation and H₂S
Phosphorus (P)250150400mg/LOften co-delivered with N when DAP is used (DAP is 21% N + 23% P). Excess is harmless; deficiency rare with DAP
Potassium (K)400300800mg/LMajor intracellular cation — osmotic balance against high sugar/ethanol. Higher targets for VHG
Magnesium (Mg)10050250mg/LCritical for ethanol tolerance — stabilises membranes. Target >3 mM (≈75 mg/L) free Mg²⁺; push to 150–250 mg/L for VHG
Sulfur (S)150100300mg/LMainly cysteine/methionine biosynthesis. Usually co-delivered with (NH₄)₂SO₄ or MgSO₄; avoid excess (H₂S production)
Calcium (Ca)5020100mg/LSignalling role only — non-limiting in most media. Often already present in process water at >20 mg/L
Sodium (Na)50500mg/LNon-essential; tolerated up to ~500 mg/L. Higher levels inhibit growth and ethanol yield
Trace metals 6 entries
Element /
Factor
Typical
target
Min.Max.UnitNotes
Iron (Fe)5230mg/LHeme/Fe-S clusters; often present in molasses/process water. Supplement defined media only
Zinc (Zn)20.55mg/LADH cofactor — the single most important trace for ethanol fermentation. <0.5 mg/L → stuck ferm, acetaldehyde accumulation, off-flavors
Manganese (Mn)0.50.22mg/LSOD cofactor; minor role. Present in most process waters
Copper (Cu)0.20.050.5mg/LCu/Zn-SOD; trace requirement. Toxic >5 mg/L
Molybdenum (Mo)0.050.020.2mg/LUltra-trace; usually present as contamination in macronutrient salts
Cobalt (Co)0.050.020.2mg/LUltra-trace; B12 precursor. Usually adequate from molasses/corn mash
Vitamins 8 entries
Element /
Factor
Typical
target
Min.Max.UnitNotes
Biotin (B8)0.10.050.3mg/LEssential — yeast cannot synthesize. Cofactor for acetyl-CoA carboxylase (fatty acid synthesis); demand elevated under ethanol stress
Thiamine (B1)2110mg/LTPP cofactor for pyruvate decarboxylase — the glycolytic enzyme generating acetaldehyde for ethanol. Industrial strains often thiamine auxotrophs
Riboflavin (B2)10.52mg/LFAD/FMN cofactor; synthesized by yeast, rarely limiting in practice
Nicotinic A. (B3)5210mg/LNAD⁺/NADP⁺ precursor; synthesized from tryptophan. Boost for amino-acid-limited media
Pantothenate (B5)5210mg/LCoenzyme A precursor. Deficiency causes stuck fermentation + H₂S; strongly correlated with sluggish fermentations in fuel ethanol
Pyridoxine (B6)10.52mg/LPLP cofactor for aminotransferases; usually synthesized adequately
Folic A. (B9)0.20.10.5mg/LOne-carbon metabolism; synthesized by yeast, rarely limiting
Inositol251050mg/LPhosphatidylinositol precursor — membrane structural role. Supplementation improves ethanol tolerance above 10% v/v
Anaerobic Lipid Factors · essential under anaerobiosis 2 entries
Element /
Factor
Typical
target
Min.Max.UnitNotes
Ergosterol10520mg/LEssential under anaerobiosis. Yeast cannot synthesize sterols without O₂. Fermentations lacking ergosterol stall at 40–60% sugar utilisation. Add as EtOH/Tween-80 emulsion
Tween-80 (oleate source)5001001000mg/LSupplies C18:1 unsaturated fatty acid. Anaerobic desaturation impossible → oleate must be exogenous. Standard fuel ethanol dose: 0.5 g/L Tween-80
Ethanol Fermentation — Process Notes 12 topics
TopicGuidance
Ethanol yield (YE/S)Theoretical Gay-Lussac max = 0.511 g EtOH/g glucose. Industrial strains achieve 0.45–0.49 g/g (88–96% of theoretical). Glycerol + biomass + organic acids account for the ~3–12% loss.
Biomass yield (YX/S)0.03–0.08 g DCW/g sugar under anaerobic conditions — an order of magnitude lower than aerobic propagation (0.45–0.55). Nitrogen and vitamin demands scale with this small biomass.
Glycerol byproduct2–5% of sugar is diverted to glycerol as a redox sink to reoxidise NADH from biosynthesis. Increases under osmotic stress (VHG, > 250 g/L sugar) to ~6–8%.
CO₂ stoichiometryC₆H₁₂O₆ → 2 C₂H₅OH + 2 CO₂ gives a CO₂/EtOH mass ratio of 88/92 = 0.957. Expect ≈0.44 g CO₂ per g sugar fermented (at YE/S=0.46).
Free amino nitrogen (FAN)Target 200–400 mg FAN/L for normal gravity (12–15% v/v), 400–700 mg/L for VHG (>17% v/v). DAP is standard; supplement with yeast extract or CSL for complex N if needed.
Magnesium & ethanol toleranceMg²⁺ stabilises membranes against ethanol damage. Target > 3 mM free Mg²⁺ in broth for VHG (~75 mg/L). Critical for productivity at > 10% v/v ethanol.
Zinc & ADH activityZn²⁺ is the active-site metal of alcohol dehydrogenase (ADH). Deficiency (< 0.5 mg/L) causes sluggish fermentation and acetaldehyde accumulation. 1–2 mg/L Zn²⁺ added as ZnSO₄ is typical.
Biotin & pantothenateThese two vitamins are the most common vitamin limitations in ethanol fermentation. Pantothenate deficiency elevates H₂S production and stalls fermentation at 60–80% completion. Supplement even if yeast extract is used.
VHG operation (> 17% v/v)Use fed-batch sugar addition to avoid osmotic shock. Supplement with unsaturated fatty acids (oleate, Tween-80) and sterols (ergosterol) — anaerobic synthesis is impaired and these become essential for membrane integrity.
pH & temperatureOptimal pH 4.0–5.0 (lower than propagation — suppresses contaminants). Temperature 30–34 °C for regular strains, up to 38–40 °C for thermotolerant strains. Ethanol tolerance drops sharply > 35 °C.
Trace element stocksPrepare 1000× concentrated trace stock in dilute HCl (pH 1–2) to prevent precipitation. Autoclave or filter-sterilise separately from macronutrients and sugar to avoid Maillard reactions.
Vitamin stabilityThiamine, riboflavin, folate are heat/light-labile. Filter-sterilise (0.2 µm) and add post-autoclaving. Biotin stock (0.2% w/v) stable at 4 °C for weeks; pantothenate hydrolyses above pH 7 — keep acidic.
Test against target:
Test Medium  ·  coverage by category  ·  click headers to expand/collapse
Macronutrients
Compound Salt / Note Amount added (g) Coverage Max vol. (L)
Trace Metals
Compound Salt / Note Amount added (g) Coverage Max vol. (L)
Vitamins
Compound Salt / Note Amount added (g) Coverage Max vol. (L)
Anaerobic Lipid Factors · essential under anaerobiosis
Compound Salt / Note Amount added (g) Coverage Max vol. (L)
Enter compound amounts above to test the medium.

Medium Calculator — Quick Start

The calculator is organized as a two-column layout with five top-level collapsible cards: Target Production & Broth Target Concentrations on the left (inputs); Summary, Carbon Mass Balance, and Results & Tabs on the right (outputs). Each card with sub-categories opens further into Macronutrients / Trace Metals / Vitamins / Anaerobic Lipid Factors sub-collapsibles, all collapsed by default to keep the view tidy.

  1. Open Target Production → Ethanol Fermentation Targets. Enter Target Ethanol Production (default 10 L; switchable to US gallons) and Target Ethanol Titer (default 17% v/v — VHG territory; also % w/v or g/L). The calculator converts internally before running the mass balance.
  2. Open Target Production → Feedstock & Substrate. Pick a Feedstock from the 10-option dropdown (default: Corn — whole kernel). Selecting one auto-populates Moisture % and Starch Fraction. Each option carries a fermentable-sugar yield (g sugar / g dry feedstock, 0.48–1.10) shown next to the dropdown. Override Moisture (grains 12–14%, molasses ~20%, dried cassava ~12%) or Starch Fraction (% of sugar-eq from starch hydrolysis, not mass%) if your raw material differs from the defaults. Optional: enable "Credit nutrients provided by feedstock" to subtract built-in FAN / K / Mg / vitamins from the salt recipe.
  3. Open Target Production → Stoichiometric Yields & Batch %. Slide YE/S (0.38–0.50, default 0.46), YX/S (0.02–0.10, default 0.05), YGly/S (0.01–0.08, default 0.04), and the % Nutrients in Initial Batch Phase (30–100, default 100 = full batch).
  4. Click "Load Standard" in the Broth Target Concentrations card to populate all 23 nutrient rows (7 macronutrients, 6 trace metals, 8 vitamins, 2 lipid factors) with fuel-ethanol defaults. Expand any of the four nutrient sub-cards (▶ Macronutrients / Trace Metals / Vitamins / Anaerobic Lipid Factors) to edit individual targets.
  5. Read the Summary card — three snapshot-style rows of computed values:
    • Production overview: Total Sugar Required (kg / lbs / ton), Ethanol Produced (L abs. / gal / kg / lbs), Broth Volume (L / gal / hL) with biomass-produced as descriptor. Switch units via the compact Units strip at the bottom.
    • Substrate split (visible only when Starch Fraction > 0): Starch Needed (starchFrac × sugar ÷ 1.11), Direct Glucose ((1 − starchFrac) × sugar), Feedstock as-received (dry mass ÷ (1 − moisture)).
    • Enzyme loading (same trigger): α-Amylase @ 500 U/g starch, Glucoamylase @ 200 U/g starch, plus combined total. Auto-formatted as U / kU / MU based on magnitude.
    For glucose-only feedstocks (cane / beet molasses, pure sugars), the substrate + enzyme rows hide and a small italic notice replaces them.
  6. Check the Carbon Mass Balance card — the stacked horizontal bar should show 95–100% closure across Ethanol / CO₂ / Glycerol / Biomass / Other. Below 95% means missing products; above 100% means yield coefficients exceed stoichiometry and need reducing.
  7. Open Results & Tabs. Five tabs across the top:
    • Total Required — every nutrient grouped into the same 4 sub-cards (Macro / Trace / Vitamin / Lipid), each row showing the chosen salt, mass to weigh per batch, and a ✓ "covered" indicator when an element is auto-supplied as a co-element from another salt (e.g., S from MgSO₄).
    • Batch Medium & VHG Feed — splits the Total Required between the initial batch and the fed-batch supplement based on the Batch % slider.
    • Reference — typical concentrations and molar masses; also includes an Ethanol Fermentation — Process Notes collapsible with 12 topical guidance items (yield expectations, FAN targets, Mg / Zn / vitamin roles, VHG operation, pH & temperature ranges, sterility tips).
    • Test Medium — enter actual salt masses you weighed out and see coverage % per nutrient (green ≥100%, amber 50–99%, red <50%) plus the most-limiting row identified in the verdict bar.
  8. Customize individual nutrients by editing target concentrations in Broth Target Concentrations or picking different salts from the dropdowns in Total Required. Recipe updates live across all tabs.
  9. Switch to the Time-Course Simulator tab. Initial glucose, starch, FAN, Mg, Zn, ergosterol, oleate, broth volume, and target titer are already live-synced from the Medium Calc — no Import click needed for routine edits. Click Run Simulation or rely on the 180 ms auto-debounce.

Live sync: Every input change in the Medium Calculator (target ethanol, titer, feedstock, starch fraction, moisture, Y_E/S / Y_X/S / Y_Gly/S sliders, batch %, and every nutrient target) propagates automatically to the Simulator's Substrate Pools, Init Conditions, Nutrient Coupling, and Inoculum Sizing cards. The "← Import from Medium Calculator" button in the Simulator is still there as a manual refresh if you ever need to force a re-sync. All headers (outer h2-style and inner sub-collapsibles) are click-to-toggle — useful once you've configured a section.

Fit Model to Experimental Data

© 2026 FermAxiom LLC · Author: Peter Krasucki · peter.krasucki@fermaxiom.com  |  Parameter estimation & model calibration  |  v19.95

Parameter estimation — calibrate the model against observed fermentation data

Upload or paste time-course observations below (tab- or comma-separated). The simulator compares the current model prediction against your data, reports per-species R² and RMSE, and can optimise selected parameters (Nelder–Mead simplex) to best fit the observations. Use this to calibrate on pilot-scale runs before extrapolating to production, or to identify which strain/regime settings best explain a stuck or irregular ferment. Parameters are read from and written to the Time-Course Simulator tab — switch back there to see the fitted curves overlay on the full time-course charts.
Observed data
Supported column names
Parameters to fit
Check the parameters you want the optimiser to vary. Current values are read live from the Simulator tab. For a first pass, 2–4 parameters converges quickly; more than 6 risks over-fitting.

Yeast growth & substrate kinetics

max specific growth rate [0.05–0.7 h⁻¹]
half-saturation for glucose [0.1–5 g/L]
maintenance coefficient [0–1 g/g/h]
basal death rate [0.001–0.05 h⁻¹]
ethanol death sensitivity [0.001–0.05]

Yield coefficients

biomass yield [0.02–0.15 g/g]
ethanol yield [0.30–0.51 g/g]
glycerol growth-coupled [0–1.5 g/g]
lactic acid yield [0–0.05 g/g]
acetic acid yield [0–0.03 g/g]

Ethanol production (Luedeking–Piret)

growth-associated [0–2]
non-growth-associated [0–2]
ethanol growth-stop [60–200 g/L]
inhibition threshold [0–50 g/L]
Actions

Model calibration workflow

Prerequisite
Evaluate raw data quality: sampling density, missing values, replicate precision, monotonicity, noise, and what parameters the data can support estimating.
Step 1
Run the model with current parameters and score against data. Reports R², RMSE, bias per species.
Step 2
Derive parameters analytically from data (μmax, yields, LP coefficients). Apply to simulator as starting estimates.
Step 3
Nelder–Mead iterative refinement of checked parameters to minimise weighted SSE. Fine-tunes what Calculate started.