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

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slide1

PTT303 /2

PROCESS MODELLING AND SIMULATION

SEM 1 (2013/2014)

Biochemical Case Study

student should be able to
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.
outline for biochemical case study
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
slide4

Part 1

Fermentation

Section

Part 3

Purification

Section 2

Sequential modular approach

Part 2

Purification

Section 1

slide5

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.

process description
PROCESS DESCRIPTION

Part 1

Fermentation Section

separated in a disk-stack

centrifuge and the liquid is stored in tank. (storage 1)

Biomass

slide7

Part 2

Purification Section1

Part 3

Purification Section 2

slide8

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.)
product initialisation for fermentation section
PRODUCT INITIALISATION FOR FERMENTATION SECTION
  • Fermentation
  • Centifugation
  • Storage 1
fermentation
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.

continue1
Continue…

Note: Leave other values as DEFAULT

ferment 1
FERMENT-1

Final temp: 37 °C

Process time: 36 hr

Reaction extent

Enthalpy data

Aeration setting:

Auto adjust for air

(stock mixture)

Mass stoichiometry

slide17

Let’s simulate the

flowsheet & solve

the error message given

(scheduling problem)

purification section 1
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”

process flowsheeting for purification section 1
Process Flowsheeting for Purification Section 1

(Note; Right click on equipment & select “Flip (reverse direction)” to turn the equipment into reverse direction

slide20

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
diafiltration in superpro
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

continue2
Continue…..

Additional task:

Set TRANSFER-OUT-1 of

Storage1 (P-3) to follow the

duration of Filtration inDiafilter

(P-4) using Master-Slave

relationship

slide26

Simulate the Flowsheet

&

Solve The

Scheduling Error

purification section 2
PURIFICATION SECTION 2

Again, replace “STORE

-1” operation in P-5 with

“TRANSFER-OUT-1”

slide28

Process Flowsheeting for Purification Section 2

(Note: Right click on equipment & select “Flip (reverse

direction)” to turn the equipment into reverse direction

new mixture registration
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

a modify from existing mixture
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

b register from scratch
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)

let s try it
Let’s try it …

(Always remember to save your work …)

general description pba chromatography
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

check your simulation results
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.
slide41

Biochemical Case Study REPORT

Prepare a detail report of the BIOCHEMICAL CASE STUDY and attached together

your simulation result (Gantt Chart)