1. ERT 320 Bio-Separation Engineering
Semester /2013
Huzairy Hassan
School of Bioprocess Engineering
UniMAP

2. Integrated Bio-Separation Schemes

3. Integrated Bio-Separation Schemes
“Ability to propose bio-separation techniques/processes and RIPP (Recovery, Isolation, Purification and Polishing) scheme”
Integrated Bio-Separation Schemes

4. BIOPROCESS DESIGN
INTEGRATED 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 the required size of process equipment and supporting utilities?
What is total capital investment?
Can the product be produced in an existing facility or new plant required?
What is the optimum batch size? How long does a single batch take?
What is the manufacturing cost?

5. BIOPROCESS DESIGN INTEGRATED BIO-SEPARATION PROCESSES What if ???
How much product can be generated per year?
What is the demand for various resources (raw mat, labor, utilities)?
How much???
What is the environmental impact of the process?
What if ???
What is ???

6. INTEGRATED BIO-SEPARATION PROCESSES
BIOPROCESS DESIGN
INTEGRATED 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

7. SYNTHESIS OF BIO-SEPARATION PROCESS
BIOPROCESS DESIGN
SYNTHESIS OF BIO-SEPARATION PROCESS

8. SYNTHESIS OF BIO-SEPARATION PROCESS
BIOPROCESS DESIGN
SYNTHESIS OF BIO-SEPARATION PROCESS
Rules of thumb (heuristics):
Remove the most plentiful impurities first
Remove the easiest-to-remove impurities first
Make the most difficult and expensive separations last
Select processes that make use of the greatest differences in the properties of the product and its impurities
Select and sequence processes that exploit different separation driving forces.

10. Primary Recovery Stages
Intracellular Products
Extracellular Products
Cell Harvesting (1)
Centrifugation and membrane filtration
Cell Disruption
Homogenizers or bead mills
Biomass Removal (2)
Rotary vacuum filtration, centrifugation, membrane filtration
Product Extraction / Adsorption
Removal of Cell Debris
Centrifugation, microfiltration, extraction, etc

11. Intermediate Recovery Stages
Product Concentration
(1) & (2)
Product Renaturation
Ultrafiltration
Reverse Osmosis
For solubilization of products (protein) in inclusion bodies
Evaporation
Precipitation
Distillation

12. Final Purification Stages
Chromatography (3)
Crystallization & Fractional Precipitation
Dehydration & Solvent Removal

13. Process / Biochemical Process Simulator
BIOPROCESS DESIGN
PROCESS ANALYSIS
Process / Biochemical Process Simulator
 SuperPro Designer

14. BIOPROCESS DESIGN PROCESS ECONOMICS Operating Cost Estimation
 Raw materials, labor, consumables, Lab/QC/QA, Waste treatment & Disposal, Utilities, Equipment-dependent Costs, Miscellaneous
Capital Cost Estimation
Direct fixed capital (DFC)
Working capital
Start-up & Validation costs
Profitability Analysis
 Gross margin, ROI, Payback time

15. 1) Citric Acid Production
Production Plant
1) Citric Acid Production

17. 2) Human Insulin Production
Production Plant
2) Human Insulin Production

19. 3) Therapeutic Monoclonal Antibody Production
Production Plant
3) Therapeutic Monoclonal Antibody Production

21. ANY QUESTIONS
THANK YOU