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ERT 320 Bio-Separation Engineering

ERT 320 Bio-Separation Engineering. Semester 2 2012/2013 Huzairy Hassan School of Bioprocess Engineering UniMAP. Integrated Bio-Separation Schemes. “Ability to propose bio-separation techniques/processes and RIPP (Recovery, Isolation, Purification and Polishing) scheme ”.

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ERT 320 Bio-Separation Engineering

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  1. ERT 320Bio-Separation Engineering Semester 2 2012/2013 Huzairy Hassan School of Bioprocess Engineering UniMAP

  2. Integrated Bio-Separation Schemes

  3. “Ability topropose bio-separation techniques/processes and RIPP (Recovery, Isolation, Purification and Polishing) scheme” Integrated Bio-Separation Schemes

  4. BIOPROCESS DESIGN INTEGRATED BIO-SEPARATION PROCESSES - Given a product and a desired annual production rate (plant throughput), bioprocess design endeavors to answer the following questions: What are required amounts of raw materials and utilities? What is the required size of process equipment and supporting utilities? What is total capital investment? Can the product be produced in an existing facility or new plant required? What is the optimum batch size? How long does a single batch take? What is the manufacturing cost?

  5. BIOPROCESS DESIGN INTEGRATED BIO-SEPARATION PROCESSES How much product can be generated per year? What is the demand for various resources (raw mat, labor, utilities)? How much??? What is the environmental impact of the process? What if ??? What is ???

  6. BIOPROCESS DESIGN INTEGRATED BIO-SEPARATION PROCESSES • Process design is the conceptual work done prior to building, expanding, or retrofitting a process plant. • It consists of 2 main activities: Process synthesis Process analysis Is the selection and arrangement of a set of unit operations (process steps) capable of producing the desired product at an acceptable cost and quality. Is the evaluation and comparison of different process synthesis solutions

  7. BIOPROCESS DESIGN SYNTHESIS OF BIO-SEPARATION PROCESS

  8. BIOPROCESS DESIGN SYNTHESIS OF BIO-SEPARATION PROCESS Rules of thumb (heuristics): • Remove the most plentiful impurities first • Remove the easiest-to-remove impurities first • Make the most difficult and expensive separations last • Select processes that make use of the greatest differences in the properties of the product and its impurities • Select and sequence processes that exploit different separation driving forces.

  9. Primary Recovery Stages Intracellular Products Extracellular Products • Cell Harvesting (1) • Centrifugation and membrane filtration • Cell Disruption • Homogenizers or bead mills • Biomass Removal (2) • Rotary vacuum filtration, centrifugation, membrane filtration Product Extraction / Adsorption • Removal of Cell Debris • Centrifugation, microfiltration, extraction, etc

  10. Intermediate Recovery Stages Product Concentration (1) & (2) Product Renaturation Ultrafiltration Reverse Osmosis For solubilization of products (protein) in inclusion bodies Evaporation Precipitation Distillation

  11. Final Purification Stages Chromatography(3) Crystallization & Fractional Precipitation Dehydration & Solvent Removal

  12. BIOPROCESS DESIGN PROCESS ANALYSIS Process / Biochemical Process Simulator  SuperPro Designer

  13. BIOPROCESS DESIGN PROCESS ECONOMICS Operating Cost Estimation  Raw materials, labor, consumables, Lab/QC/QA, Waste treatment & Disposal, Utilities, Equipment-dependent Costs, Miscellaneous • Capital Cost Estimation • Direct fixed capital (DFC) • Working capital • Start-up & Validation costs Profitability Analysis  Gross margin, ROI, Payback time

  14. Production Plant 1) Citric Acid Production

  15. Production Plant 2) Human Insulin Production

  16. Production Plant 3) Therapeutic Monoclonal Antibody Production

  17. ANY QUESTIONS THANK YOU

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