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Conceptual design methodology for the configuration and procedural training with an operating training simulator (OTS) in a large-scale plant for commercial bio-ethanol production is described. The aim of the study is to show how the methodology provides a powerful way for finding the best configuration and training structure of the OTS before constructing and implementing the software of the OTS. The OTS principle, i.e., to use a computer-based virtual representation of the real process plant intended for efficient training of process operators, has long since been applied in aviation and process industries for more efficient and flawless operations. By using the conceptual design methodology (sometimes referred to as bio-mechatronics) a variety of OTS configurations with this capacity was generated. The systematic approach of for targeting the users' (i.e., the plant management and process operators) needs resulted in better understanding and efficiency in training of hands-on skills in operating the plant. The training included general standard operating procedures for running the plant under normal operation conditions with different starch materials, handling of typical frequent disturbances as well as acting in situations not described in the standard operation procedures and applying trouble-shooting.

BACKGROUND During recent years several computer‐based operator training simulators (OTS) have been developed that are suitable for the virtual training of operators and other professionals. In the field of bioprocess engineering OTS are rarely used. Furthermore, the effects of using training simulators in bioprocess applications have not been evaluated. RESULTS The OTS BioProcessTrainer was applied to bioreactor operations for two biological processes, Saccharomyces cerevisiae, for ethanol production, and recombinant Escherichia coli, for production of green fluorescence protein (GFP). The simulator used a multi‐shell model platform that described the biological and physical conditions of the bioreactor for the two bioprocess systems. The simulator enabled the user to plan, operate and control the processes in real or accelerated time. The training resulted in improved ability to manage the whole bioreactor procedure for the two processes. CONCLUSION The study showed that the simulator can be an efficient tool for training of operation, optimization and control of bioprocesses. The mathematical model framework of the simulator can be adapted to a variety of industrial bioprocesses. Thus, it appears likely that this type of OTS may serve as a useful resource in industry for training and continuing education of plant operators and engineers. © 2013 Society of Chemical Industry