Progress Report – Week 9

Section AC, Group 2Presented by Andrew Amodei

Teammates: David Bergsman, Michael Huang, Elizabeth Lam

May 24th, 2012

Goals of the Week• Finish individual design projects– Water for injection system– Facility layout– Downstream columns– Equipment and labor scheduling

• Finish debugging spreadsheet• FEMA analysis• Update stream tables and PFD• Complete and submit Phase II report

Gantt Chart

Team progress• Finished debugging spreadsheet• Updated stream tables• Updated PFD• Finalizing individual design projects• Finalizing FEMA analysis

Facility layout• Color-coded rooms• Clean steam, WFI, air, O2, CO2 lines• Waste lines and neutralization tanks• Additional holding tanks• Personnel support space• Sized raw material and product warehouse• Added personnel and material flow arrows

Facility layout

Chromatography columns• Finalized chromatography column parameters• Determined pump, pipe, and valve requirements

Chromatography column results Criteria Protein A IEX HIC

Resin MabSelect Sepharose FFPhenyl

Sepharose6 FF (high sub)

Number 2 2 2Diameter [cm] 80 100 100

Flow Rate [cm/hr] 100 100 100

Average Process Time [hr]

27.4 9.5 27.5

Pump and pipe specifications

Pump Pipe

Type Positive Displacement Material Stainless

Steel

Power [hp] 1 Diameter [cm] 13

Capacity [L/min] 45.42 Unit Cost [$/1.5m] 100

Unit Price [$] 8,500 Pipeline Distance

[m] 769

Number 14 Number of Valves 53

Scheduling• Optimization of scheduling complete• Results:

Optimized scheduling details

Criteria Value Comment

Number of seed train rooms 2

Increases flexibility/reduced

operating time

Downstream lot size 31,000 L

Upstream train number 6

Labor scheduling

Position Number of personnelSeed train room 2 per roomBioreactor room 2 per roomMedia production 2Downstream process 2 per downstream processMixing buffer solution 2Autoclave operation 2WFI system 2Shift mananager Seed train 1 Bioreactor 1 Primary recovery 1 Chromatography/TFF 1

Water for injection• Compiled equipment inventory• Calculated equipment and operating costs• Added and sized holding tanks• Determined pump types and number• Sized and priced deionization unit

Equipment type and costEquipment Type Number Cost [$]

Clean steam generator Steris 450-T 1 97500

Deionization unit Siemens FlexTrex36 1 30355

Holding tanks Stainless steel 2 37078

Pumps Peristaltic Hose 4 25400

Vapor compression unit Stilmas 4700-T 2 1900000Total: 2090334

Water for injection

Major results• Process design and optimization completed• Individual and Phase II reports nearing completion• Economic analysis over 30 year plant life:

0 5 10 15 20 25 300

5,000,000,000

10,000,000,000

15,000,000,000

20,000,000,000

Discounted future profit

Plant lifetime [years]

Economic analysis Parameter Basecase Disposable

Fixed Capital Investment [billion $] 0.13 0.09Total Operating Costs [billion $] 9.1 8.94NPV [billion $] 158EACF [billion $] 8.0Future Worth of Profit [billion $] 383

Future goals• Redesign facility layout for optimized case• Separate number of seed trains from number

of bioreactors.• Set up seed train to handle arbitrary volume /

cell sizes.• Prepare for presentation• Rest

Questions?

Team Questions• Any other economic factors to consider aside

from HVAC costs?• Does my ethics report grade affect my team’s

overall score?