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Insulin Production Design Project

Insulin Production Design Project. Fermentor Optimization. Group Members: Shaina Dinsdale Mike Hull Dean Latham Chris Tovee. Source: http://www.ingenious.org.uk. Outline. Fermentors in general Alternatives- Batch vs CSTR Our Design Design method Cost and Suppliers Questions.

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Insulin Production Design Project

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  1. Insulin Production Design Project Fermentor Optimization Group Members: Shaina Dinsdale Mike Hull Dean Latham Chris Tovee Source: http://www.ingenious.org.uk

  2. Outline • Fermentors in general • Alternatives- Batch vs CSTR • Our Design • Design method • Cost and Suppliers • Questions

  3. Quick Insulin Facts • Initial concentrations of insulin in the starting material is between 0.1 and 1.0 g/L • Selling price is $100,000 /kg

  4. Fermentors • Knowledge of: • kinetics, material, energy balances of biological reactions, fermentation broth, mass/heat transfer characteristics • Process Parts • Vessel • Aeration/Agitation • Temperature controls

  5. Bioreactor Selection Criterion • Productivity • 4 phases: lag, growth, harvesting, prep • Genetic Stability • Cell mutations and cell generations • Operability and Reliability • Variation in quality • Maintenance

  6. Bioreactor Alternatives CSTR • Advantages • Efficient • Constant product quality, low labour costs • Disadvantages • Infection in system • Inflexible • Strain mutations Batch • Advantages • versatility, sterilization, low strain mutation • 100% substrate conversion • Disadvantages • high labour cost • Down time • Effects on downstream process unit design

  7. Our Fermentor • 72 hour start up for cell build up • Continuous for production of insulin • Agitation and aeration, baffles, cooling coils

  8. Unit Operation

  9. Assumptions used • Type 1 Microbial growth • Relate X, S and P by yield coefficients • Assumed glucose feed rate equaled the rate of glucose consumption • µ=D because of continuous flow reactor • A density of 1.1 kg/L because 97% of input is water • Used literature values for Ccrit and YO2/X

  10. Design Method • Designed to be kinetically limited • Calculated desired kLa based on: • Assumed a height to diameter ratio of 3-2 • Used empirical correlations between Di, Dt, Ht, N and P to meet kLa

  11. Summary of Fermentor Design

  12. Operating Conditions • Temperature of 30oC • 3 reactors to achieve desired volume of 657.1 m3 • Flow inputs were given from original design specifications • Low impeller speed for low shear

  13. Cost – Inflation • From Bank of Canada online • From 1991 to 2005 • 1991: 200,000L cost $1,669,000.00 • 2005: 200,000L cost $2,151,231.56 • 28.98% increase in 14 yrs • $226000 x 3 tanks = $6,780,000

  14. Suppliers • Sartorius BBI Systems Inc. • Formerly B. Braun Biotech • Germany • From 30L to production scale • “scalable line of fermentors to get you through your next capacity crunch” • BiOENGiNEERiNG • Switzerland • “established international reputation through its many years of commitment to biotechnology”

  15. References • http://www.bankofcanada.ca/en/rates/inflation_calc.html • http://www.eng-tips.com/viewthread.cfm?qid=109826&page=1 • Daugulis, A.J., Axford, D.B., Mc Lellan, P.J. (1991). The Economics of Ethanol Production by Extractive Fermentation. Canadian Journal of Chemical Engineering, Vol.69, April.

  16. Questions?

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