Simulation Of BioprocessERT 315

3

Modeling and Assessment in

Process Development

Process design and development

Modeling and simulation

Sustainabilityassessment

Stop

Process concept

Industrial application

LiteraturePatentsExpertknowledge

Eco-efficient

Not eco-efficient

Improvementneeded

Integrated development of bioprocesses

• 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

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

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” ?

Sequential modular approachSequential modular approach Individual equipment blocks may require

iterative solution algorithms

Overall process solution is sequential & not iterative

(Turton et al., 1998)

Sequential modular approachSequential modular approach

Objectives of simulationObjectives of simulation

ProcessThroughput

BatchSize / Batch

Cycle Time

• Raw Materials• Labor• Utilities• Capital Expenses

Product(s)

Waste

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

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

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

User Interface of SuperPro Designer

Double-Click

Detailed Modeling using Unit Procedures and OperationsDetailed Modeling using Unit Procedures and Operations

Operations Gantt ChartOperations Gantt Chart

Equipment Occupancy ChartEquipment Occupancy Chart

• 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

Resource Demand ChartResource Demand Chart

Labor Demand ChartLabor Demand Chart

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%

• 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

Stream Dialog – Env. Properties Tab

INTELLIGEN, INC.

Environmental Impact ReportEnvironmental Impact Report

Bottleneck identificationBottleneck identification

• 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

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

• 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

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