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PTT303 /2 PROCESS MODELLING AND SIMULATION SEM 1 ( 2013/2014)

PTT303 /2 PROCESS MODELLING AND SIMULATION SEM 1 ( 2013/2014). Biochemical Case Study. Student should be able to; .

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PTT303 /2 PROCESS MODELLING AND SIMULATION SEM 1 ( 2013/2014)

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  1. PTT303 /2 PROCESS MODELLING AND SIMULATION SEM 1 (2013/2014) Biochemical Case Study

  2. Student should be able to; • Develop chromatographic process to achieve the desired final product purity, combination with membrane filtration to exchange buffers and concentrate the dilute product solutions. • Create the process and identify uncertainty problem that might happen during the operations.

  3. OUTLINE FOR BIOCHEMICAL CASE STUDY • A sequential modular approach to solve for a moderate complex flowsheet • Some common unit operations in biochemical industries: • Fermenter • Disk-stack centrifugation • Diafiltration • Chromatography

  4. Part 1 Fermentation Section Part 3 Purification Section 2 Sequential modular approach Part 2 Purification Section 1

  5. PROCESS DESCRIPTION Water, microorganisms, nutrients (glucose) and air are fed into a bioreactor where at 37°C a fermentation takes place, yielding an enzyme and impurities. Biomass is separated in a disk-stack centrifuge and the liquid is stored in tank. It is then processed in a diafilter where the remaining biomass is removed (with a small loss of product). It is stored again and then loaded onto a PBA chromatography column where the enzyme binds and eluted using a WFI/NaCl mixture.

  6. PROCESS DESCRIPTION Part 1 Fermentation Section separated in a disk-stack centrifuge and the liquid is stored in tank. (storage 1) Biomass

  7. Part 2 Purification Section1 Part 3 Purification Section 2

  8. Part 1 Fermentation Section • Mode of operation: batch processing • Component registration: • Glucose • Biomass • CO2 • WFI (water for injection) • Enzyme (new-water as reference comp.) • Impurities ( new-water as reference comp.)

  9. Process Flowsheeting for Fermentation Section

  10. PRODUCT INITIALISATION FOR FERMENTATION SECTION • Fermentation • Centifugation • Storage 1

  11. FERMENTATION Initialising CHARGE operation (right click on unit procedure (Fermentation)then click add /remove operations.. Add Charge -1, Charge-2, Heat-1, Ferment-1, Transfer-Out-1.

  12. Continue…

  13. Continue… Note: Leave other values as DEFAULT

  14. FERMENT-1 Final temp: 37 °C Process time: 36 hr Reaction extent Enthalpy data Aeration setting: Auto adjust for air (stock mixture) Mass stoichiometry

  15. CENTRIFUGATION

  16. STORAGE 1

  17. Let’s simulate the flowsheet & solve the error message given (scheduling problem)

  18. PURIFICATION SECTION 1 Right click on storage; then click on add/remove operations/delete storage/add TRANSFER-OUT-1 Please delete “STORE-1” operation in P-3 & replace it with a “Transfer-Out-1”

  19. Process Flowsheeting for Purification Section 1 (Note; Right click on equipment & select “Flip (reverse direction)” to turn the equipment into reverse direction

  20. PROCESS DESCRIPTION ; Diafiltration • In diafiltration, water or some other solvent or buffer is added to the retentate to facilitate the removal of membrane-permeating species along with the water (or other solvent) during filtration. • The addition of water (or any other solvent) can be conducted either in batch or continuous mode. recycle Feed tank • In batch operation, permeable solutes are: • Cleared from the retentate by volume reduction (batch concentration); • Followed by re-dilution with water ( or other solvent); and • Re-concentration in repetitive steps

  21. Diafiltration in SuperPro Retentate (Concentrate) • In the current version of SuperPro Designer, batch concentration can precede and follow a continuous operation (true diafiltration) • Any number of batch concentration stages can be specified for each discontinuous operation. • In general, if the initial solution is dilute, a concentration step (to reduce the volume of the material) usually precedes a continuous diafiltration step. Feed tank Recycle Loop Permeate (Filtrate) • If the initial solution concentration is rather high, one usually goes directly to continuous diafiltration

  22. PRODUCT INITIALISATION FOR PURIFICATION SECTION-1 • Diafiltration • Storage 2

  23. DIAFILTRATION

  24. Continue….. Additional task: Set TRANSFER-OUT-1 of Storage1 (P-3) to follow the duration of Filtration inDiafilter (P-4) using Master-Slave relationship

  25. STORAGE 2

  26. Simulate the Flowsheet & Solve The Scheduling Error

  27. PURIFICATION SECTION 2 Again, replace “STORE -1” operation in P-5 with “TRANSFER-OUT-1”

  28. Process Flowsheeting for Purification Section 2 (Note: Right click on equipment & select “Flip (reverse direction)” to turn the equipment into reverse direction

  29. NEW MIXTURE REGISTRATION • We need a mixture of “NaCl/WFI(2M)” for this section, but this mixture is not found in the component database of SuperPro (verify this from Stock Mixture database) • 2 ways of registering this mixture: • A) MODIFY FROM EXISTING MIXTURE ‘Register as NaCl (2M) & replace the water compound in this mixture with WFI’ • B) REGISTER FROM SCRATCH Register it from scratch & fill in the physical properties that you have

  30. A)MODIFY FROM EXISTING MIXTURE • Path: Task/Edit Stock Mixtures Make sure the mass % is make up into 100% Highlight the water component, delete & replace it with WFI

  31. B)REGISTER FROM SCRATCH • Path: Task/Edit stock Mixtures Create new mixture Choose this option if you know the density of the mixture Choose this option to modify from an existing mixture (e.g. NaCl mixture)

  32. Let’s try it … (Always remember to save your work …)

  33. PRODUCT INITIALISATION FOR PURIFICATION SECTION 2 • PBA Chromatography • Storage 3

  34. GENERAL DESCRIPTION : PBA CHROMATOGRAPHY 4 different PBA Chromatography Column; 1)Column Loading (Load) 2)Column Washing (Wash) 3)Column Elution (Elute) 4)Column Regeneration (Regenerate) Regenerate

  35. STORAGE 3

  36. Check your simulation results • Check the input to your PBA chromatography • Since we specify comp binding & yield for: • Enzyme to be 100%, 90% • Impurity: 20%, 30% • The amount of enzymein the product stream: ___kg • The amount of impuritiesin the product stream should be: ___kg • Please check this out & verify this from your • simulation results.

  37. Biochemical Case Study REPORT Prepare a detail report of the BIOCHEMICAL CASE STUDY and attached together your simulation result (Gantt Chart)

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