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Simulation Of Bioprocess ERT 315 3 Modeling and Assessment in Process Development Integrated development of bioprocesses Process concept Process design and development Improvement needed Modeling and simulation Sustainability assessment Ecoefficient Industrial application Not ecoStop efficient Literature Patents Expert knowledge • Close collaboration with the process design • Additional information from patents, literature, and other external sources • Simulation used to evaluate the process and guide the R&D to the overall aim • Repeated iteratively 4 Batch/Bioprocess Modeling, Scheduling & Optimization Subject covered Modeling and optimization of batch and continuous processes Batch Process Scheduling Resources and inventory tracking Cost analysis & project economic evaluation Throughput Analysis & Debottlenecking What is “Process Simulation”? Q: What does the word “simulate” mean? Building a process model Predicting how a process would actually behave Performing an experiment (on computer) Incentives: Highly cost effective Reasonably accurate Proactive approach The Role of Process Simulation and Scheduling Tools in Product Development and Commercialization IDEA GENERATION Project Screening, Strategic Planning Development Groups PROCESS DEVELOPMENT Evaluation of Alternatives Common Language of Communication FACILITY DESIGN Equipment & Utility Sizing and Design Development Groups Process Engineering Corporate Environmental Tech Transfer MANUFACTURING On-Going Optimization, Debottlenecking Production Scheduling, Capacity Analysis Manufacturing What is a “model” ? Process Simulation and Enterprise Modeling “A model should be as simple as possible and no simpler” – Albert Einstein INTELLIGEN, INC. Sequential modular approach Individual equipment blocks may require iterative solution algorithms Overall process solution is sequential & not iterative (Turton et al., 1998) Sequential modular approach Objectives of simulation • Raw Materials • Labor • Utilities • Capital Expenses Batch Process Size Throughput / Batch Cycle Time Waste Product(s) Commercial process simulators SS Simulation Aspen Plus Dynamic Simulation Batch Oil, Gas & Petrochemicals HYSYS Solids Pinch Oleo Chemicals Specialty Chemicals Provision Design II Phys Prop Sizing & Costing Economics SuperPro Rating Sensitivity Analysis Optimization SuperPro Designer (SPD) SuperPro Designer BioPro Designer BatchPro Designer EnviroPro Designer SchedulePro Biotechnology Bio-Fuels Fine Chemicals Pharmaceuticals Food Processing Mineral Processing Water Purification Wastewater Treatment Air Pollution Control Scheduling and Debottlenecking of Multi-Product Facilities Available tools •Intuitive user interface •Wide variety of unit operation models •Databases for components and mixtures •M&E Balances of Integrated Processes • Equipment Sizing and Costing • Project Economic Evaluation • Process Scheduling & Cycle Time Analysis • Throughput Analysis & Debottlenecking • Environmental Impact • Detailed Reports and Charts for the Above User Interface of SuperPro Designer Detailed Modeling using Unit Procedures and Operations Double-Click Operations Gantt Chart Equipment Occupancy Chart Scheduling Questions • How can I schedule production during the next 6-18 months? • How can I schedule operations in an R&D facility? • How to adjust scheduling if priorities change? • Can I fit a new product into my facility? Resource Demand Chart Labor Demand Chart Cost Breakdown Consumables $0.65/g 29.1% Raw materials $0.88/g 39.6% Raw Materials Equipment Labor Consumables Lab/QC/QA Waste Trtm/Disp Utilities Facility $0.54/g 24.4% Cost Analysis Questions • What is the required capital investment for a new plant? • How much would it cost to make a kilo of product? • Which process is better for making this product? A or B? • How can I reduce the operating cost of a process? Environmental Report Stream Dialog – Env. Impact Properties Tab INTELLIGEN, INC. Bottleneck identification Debottlenecking Questions • How much product can I make in this plant? • What limits the current production level? • What is the capital investment for increasing production? Steps in the development of a bioprocess Literature/patent review Biocatalyst screening Development steps Biocatalyst optimization Medium and reaction condition optimization Selection of downstream steps Identification of PFD Optimization of unit operations Plant size Scale-up : Lab – technical - industrial Approval, clinical trials Process modeling and uncertainty analysis Economic and environmental assessment Development process Product idea Production • • • • • • • • • • • Goal of every process development: product Product- should have a market, potential market, sufficient size that economically justifies the required environment Required literature and patent review – to clarify if there are similar products already on the market or in the development Find a biocatalyst (organism or an enzyme that catalyses the formation of the desired product)- to reach an economically feasible product yield and concentration The medium and reaction conditions are adjusted enable the best performance of the catalyst- medium should be as simple and inexpensive as possible and the reaction conditions should provide the best environment for the biocatalyst The process flow diagram (PFD) put together all the operation All unit operations have to be chosen and connected in an efficient and robust manner- to maximize the overall yield Determined the size plant- validate the market share of the product estimated at the beginning Scale up the process Plan and implement the clinical trials for pharmaceuticals Build a process models to estimate the material balance, energy consumption, labor requirement and equipment needed Bioprocess environment Product Market/marketing Health and environmental impact Legal/regulatory aspects Safety Biocatalyst Molecular biology Microbiology Biochemistry Cultivation Strategic decisions/ business strategy Process Biochemical and process engineering modeling Supply chain Cost analysis Patents, Intellectual property
