Simulation Of Bioprocess ERT 315. 3 Modeling and Assessment in Process Development.
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Transcript of Simulation Of Bioprocess ERT 315. 3 Modeling and Assessment in Process Development.
![Page 1: Simulation Of Bioprocess ERT 315. 3 Modeling and Assessment in Process Development.](https://reader030.fdocuments.net/reader030/viewer/2022033105/56649f1b5503460f94c31656/html5/thumbnails/1.jpg)
Simulation Of BioprocessERT 315
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3
Modeling and Assessment in
Process Development
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Process design and development
Modeling and simulation
Sustainabilityassessment
Stop
Process concept
Industrial application
LiteraturePatentsExpertknowledge
Eco-efficient
Not eco-efficient
Improvementneeded
Integrated development of bioprocesses
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• 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
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4
Batch/Bioprocess Modeling,Scheduling & Optimization
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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
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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
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IDEA GENERATIONProject Screening, Strategic Planning
PROCESS DEVELOPMENTEvaluation of Alternatives
Common Language of Communication
FACILITY DESIGNEquipment & Utility Sizing and Design
MANUFACTURINGOn-Going Optimization, Debottlenecking
Production Scheduling, Capacity Analysis
Development Groups
Development GroupsProcess EngineeringCorporate EnvironmentalTech Transfer
Manufacturing
The Role of Process Simulation and Scheduling Tools inProduct Development and Commercialization
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Process Simulation and Enterprise Modeling
INTELLIGEN, INC.
“A model should be as simple as possibleand no simpler” – Albert Einstein
What is a “model” ?What is a “model” ?
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Sequential modular approachSequential modular approach Individual equipment blocks may require
iterative solution algorithms
Overall process solution is sequential & not iterative
(Turton et al., 1998)
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Sequential modular approachSequential modular approach
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Objectives of simulationObjectives of simulation
ProcessThroughput
BatchSize / Batch
Cycle Time
• Raw Materials• Labor• Utilities• Capital Expenses
Product(s)
Waste
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Commercial process simulatorsCommercial process simulators
Oil, Gas &Petrochemicals
Oleo Chemicals
Specialty Chemicals
Aspen Plus
HYSYS
Provision
Design II
SuperPro
SS Simulation
Dynamic Simulation
Batch
Solids
Pinch
Phys Prop
Sizing & Costing
Economics
Rating
Sensitivity Analysis
Optimization
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SuperPro Designer (SPD)SuperPro Designer (SPD)
Water PurificationWastewater TreatmentAir Pollution Control
BioPro Designer
SuperPro Designer
BatchPro Designer
EnviroPro Designer
BiotechnologyBio-Fuels
Fine ChemicalsPharmaceuticalsFood ProcessingMineral Processing
SchedulePro Scheduling and Debottlenecking of Multi-Product Facilities
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Available toolsAvailable 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
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User Interface of SuperPro Designer
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Double-Click
Detailed Modeling using Unit Procedures and OperationsDetailed Modeling using Unit Procedures and Operations
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Operations Gantt ChartOperations Gantt Chart
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Equipment Occupancy ChartEquipment Occupancy Chart
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• 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?
Scheduling Questions Scheduling Questions
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Resource Demand ChartResource Demand Chart
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Labor Demand ChartLabor Demand Chart
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Raw Materials
Equipment
Labor
Consumables
Lab/QC/QA
Waste Trtm/Disp
Utilities
Cost Breakdown
Raw materials$0.88/g39.6%
Facility$0.54/g24.4%
Consumables$0.65/g29.1%
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• 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?
Cost Analysis QuestionsCost Analysis Questions
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Stream Dialog – Env. Properties Tab
INTELLIGEN, INC.
Environmental Impact ReportEnvironmental Impact Report
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Bottleneck identificationBottleneck identification
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• How much product can I make in this plant?
• What limits the current production level?
• What is the capital investment for increasing production?
Debottlenecking QuestionsDebottlenecking Questions
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Steps in the development of a bioprocess
Dev
elo
pm
ent
step
s
Development processProduct idea
Production
Literature/patent review
Biocatalyst screening
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
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• 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
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BiocatalystMolecular biology
MicrobiologyBiochemistryCultivation
ProcessBiochemical and process engineering
modeling
Bioprocess environment
Cost analysis
Supplychain
Strategic decisions/business strategy
Health andenvironmentalimpact
Patents,Intellectual property
Legal/regulatoryaspects
SafetyProduct Market/marketing