ERT 320Bio-

Separation Engineering

Semester 2 2012/2013Huzairy Hassan

School of Bioprocess EngineeringUniMAP

Integrated Bio-Separation Schemes

“Ability to propose bio-separation techniques/processes and RIPP

(Recovery, Isolation, Purification and Polishing) scheme”

Integrated Bio-Separation Schemes

BIOPROCESS DESIGNINTEGRATED 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 total capital

investment?

What is the required size of process equipment

and supporting utilities?

Can the product be produced in an existing

facility or new plant required?

What is the manufacturing

cost?

What is the optimum batch size?

How long does a single batch take?

BIOPROCESS DESIGNINTEGRATED BIO-SEPARATION

PROCESSESHow much

product can be generated per

year?

How much???

What is the demand for various resources (raw mat, labor, utilities)?

What if ???What is ???

What is the environmental impact

of the process?

BIOPROCESS DESIGNINTEGRATED 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

BIOPROCESS DESIGN

SYNTHESIS OF BIO-SEPARATION PROCESS

BIOPROCESS DESIGNSYNTHESIS OF BIO-SEPARATION PROCESS

Rules of thumb (heuristics):(1) Remove the most plentiful impurities first

(2) Remove the easiest-to-remove impurities first

(3) Make the most difficult and expensive separations last

(4) Select processes that make use of the greatest differences in the properties of the product and its impurities

(5) Select and sequence processes that exploit different separation driving forces.

Primary Recovery Stages

Intracellular Products

Extracellular Products

Cell Harvesting (1)Centrifugation and membrane

filtration

Cell DisruptionHomogenizers

or bead mills

Removal of Cell DebrisCentrifugation,

microfiltration, extraction, etc

Product Extraction / Adsorption

Biomass Removal (2)Rotary vacuum

filtration, centrifugation,

membrane filtration

Intermediate Recovery Stages

Product Concentration

(1) & (2)

Product Renaturation

Ultrafiltration Reverse Osmosis

PrecipitationEvaporation

For solubilization of products (protein) in

inclusion bodies

Distillation

Final Purification Stages

Chromatography (3)

Crystallization & Fractional Precipitation

Dehydration & Solvent Removal

BIOPROCESS DESIGN

PROCESS ANALYSIS

Process / Biochemical Process Simulator

SuperPro Designer

BIOPROCESS DESIGN

PROCESS ECONOMICS

Capital Cost EstimationDirect fixed capital (DFC)

Working capitalStart-up & Validation costs

Operating Cost Estimation Raw materials, labor,

consumables, Lab/QC/QA, Waste treatment & Disposal, Utilities, Equipment-dependent Costs,

Miscellaneous

Profitability Analysis Gross margin, ROI,

Payback time

Production Plant

1) Citric Acid Production

Production Plant

2) Human Insulin Production

Production Plant

3) Therapeutic Monoclonal Antibody Production

ANY QUESTIONS

THANK YOU