1. Simulation Of Bioprocess ERT 315

2. Batch/Bioprocess Modeling, Scheduling & Optimization

3. 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

4. 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

5. 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

6. Sequential modular approach
Individual equipment blocks may require iterative solution algorithms
Overall process solution is sequential & not iterative
(Turton et al., 1998)

7. Sequential modular approach

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

9. 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

10. 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

11. 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

12. User Interface of SuperPro Designer

13. Detailed Modeling using Unit Procedures and Operations
Double-Click

14. Operations Gantt Chart

15. Equipment Occupancy Chart

16. 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?

17. Resource Demand Chart

18. Labor Demand Chart

19. Cost Breakdown Consumables $0.65/g 29.1% Raw materials $0.88/g 39.6%
Facility
$0.54/g
24.4%

20. 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?

21. Environmental Impact Report

22. Bottleneck identification

23. 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?