Simulation Of Bioprocess ERT 315

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 Development Groups Process Engineering Corporate Environmental Tech Transfer FACILITY DESIGN Equipment & Utility Sizing and Design MANUFACTURING On-Going Optimization, Debottlenecking Production Scheduling, Capacity Analysis Manufacturing

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 Integrated BioProcess Raw Materials Labor Utilities Capital Expenses Process Throughput Batch Size / Cycle Time  Product(s) Waste

Commercial process simulators SS Simulation Dynamic Simulation Aspen Plus Batch Oil, Gas & Petrochemicals HYSYS Solids Pinch Oleo Chemicals Provision Phys Prop Sizing & Costing Specialty Chemicals Design II Economics SuperPro Rating Sensitivity Analysis Optimization

SuperPro Designer (SPD) Biotechnology Bio-Fuels BioPro Designer Fine Chemicals Pharmaceuticals Food Processing Mineral Processing BatchPro Designer Water Purification Wastewater Treatment Air Pollution Control EnviroPro Designer SchedulePro 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% 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 Impact Report

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?