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ERT 315/4 SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

ERT 315/4 SIMULATION OF BIOPROCESS SEM 1 (2010/2011). Modeling & Simulation of Bioprocess: ‘BIOCHEMICAL CASE STUDY’. By; Mrs Hafiza Binti Shukor. Student should be able to; .

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ERT 315/4 SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

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  1. ERT 315/4 SIMULATION OF BIOPROCESS SEM 1 (2010/2011) Modeling & Simulation of Bioprocess: ‘BIOCHEMICAL CASE STUDY’ By; MrsHafizaBintiShukor

  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 uncertainty problem that might happen during the operations. ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  3. OUTLINE FOR BIOCHEMICAL CASE STUDY • A sequential modular approach to solve for a moderate complex flowsheet • Some common unit operations in biochemical industries: • Fermentor • Disk-stack centrifugation • Diafiltration • Chromatography ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  4. Part 1 Fermentation Section Part 3 Purification Section 2 Sequential modular approach Part 2 Purification Section 1 ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  5. PROCESS DESCRIPTION Part 1 Fermentation Section separated in a disk-stack centrifuge and the liquid is stored in tank. (storage 1) Biomass ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  6. Part 2 Purification Section1 Part 3 Purification Section 2 ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  7. 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.) ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  8. Process Flowsheeting for Fermentation Section ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  9. PRODUCT INITIALISATION FOR FERMENTATION SECTION • Fermentation • Centifugation • Storage 1 ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  10. 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. ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  11. Continue… ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  12. Continue… Note: Leave other values as DEFAULT ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  13. FERMENT-1 Final temp: 37 °C Process time: 36 hr Reaction extent Enthalpy data Aeration setting: Auto adjust for air (stock mixture) Mass stoichiometry ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  14. CENTRIFUGATION ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  15. STORAGE 1 ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  16. Let’s simulate the flowsheet & solve the error message given (scheduling problem) ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  17. 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” ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  18. Process Flowsheeting for Purification Section 1 (Note; Right click on equipment & select “Flip (reverse direction)” to turn the equipment into reverse direction ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  19. 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 ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  20. 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 ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  21. PRODUCT INITIALISATION FOR PURIFICATION SECTION-1 • Diafiltration • Storage 2 ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  22. DIAFILTRATION ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  23. Continue….. Additional task: Set TRANSFER-OUT-1 of Storage1 (P-3) to follow the duration of Filtration inDiafilter (P-4) using Master-Slave relationship ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  24. STORAGE 2 ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  25. Simulate the Flowsheet & Solve The Scheduling Error ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  26. PURIFICATION SECTION 2 Again, replace “STORE -1” operation in P-5 with “TRANSFER-OUT-1” ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  27. Process Flowsheeting for Purification Section 2 (Note: Right click on equipment & select “Flip (reverse direction)” to turn the equipment into reverse direction ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  28. 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 ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  29. 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 ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  30. 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) ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  31. Let’s try it … (Always remember to save your work …) ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  32. PRODUCT INITIALISATION FOR PURIFICATION SECTION 2 • PBA Chromatography • Storage 3 ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  33. GENERAL DESCRIPTION : PBA CHROMATOGRAPHY 4 Types of PBA Chromatography Column; 1)PBA Column Loading (Load) 2)Column Washing (Wash) 3)Column Elution (Elute) 4)Column Regeneration (Regenerate) ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  34. ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  35. ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  36. ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  37. ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  38. STORAGE 3 ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  39. 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. ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

  40. Biochemical Case Study REPORT Prepare a detail report of the BIOCHEMICAL CASE STUDY and attached together your simulation result (Gantt Chart) This INDIVIDUAL report is COMPULSORY to submit on Friday (24 Sept. 2010) ERT 315/4SIMULATION OF BIOPROCESS SEM 1 (2010/2011)

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