ERT 320
Bio-Separation
Engineering
Semester 2 2012/2013
Huzairy Hassan
School of Bioprocess Engineering
UniMAP
Integrated BioSeparation Schemes
“Ability to propose bio-separation
techniques/processes and RIPP
(Recovery, Isolation, Purification and
Polishing) scheme”
Integrated Bio-Separation Schemes
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?
Can the product be
produced in an existing
facility or new plant
required?
What is the required size
of process equipment
and supporting utilities?
What is the
optimum batch
size? How long does
a single batch take?
What is total
capital
investment?
What is the
manufacturing
cost?
BIOPROCESS DESIGN
INTEGRATED BIO-SEPARATION PROCESSES
How much
product can be
generated per
year?
What is the demand for
various resources (raw
mat, labor, utilities)?
How much???
What if ???
What is the
environmental impact
of the process?
What is ???
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
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.
Process analysis
Is the evaluation and
comparison of different
process synthesis
solutions
BIOPROCESS DESIGN
SYNTHESIS OF BIO-SEPARATION
PROCESS
BIOPROCESS DESIGN
SYNTHESIS OF BIO-SEPARATION PROCESS
Rules of thumb (heuristics):
(1) Remove the most plentiful impurities first
(2) Remove the easiest-to-remove impurities first
(3) Make the most difficult and expensive
separations last
(4) Select processes that make use of the greatest
differences in the properties of the product and its
impurities
(5) Select and sequence processes that exploit
different separation driving forces.
Primary
Recovery Stages
Intracellular
Products
Cell Harvesting (1)
Centrifugation
and membrane
filtration
Product
Extraction /
Adsorption
Extracellular
Products
Cell Disruption
Homogenizers
or bead mills
Removal of Cell Debris
Centrifugation,
microfiltration,
extraction, etc
Biomass Removal (2)
Rotary vacuum
filtration,
centrifugation,
membrane filtration
Intermediate
Recovery Stages
Product
Concentration
(1) & (2)
Reverse
Osmosis
Ultrafiltration
Evaporation
Precipitation
Distillation
Product
Renaturation
For solubilization of
products (protein) in
inclusion bodies
Final Purification
Stages
Chromatography
(3)
Crystallization &
Fractional Precipitation
Dehydration & Solvent
Removal
BIOPROCESS DESIGN
PROCESS ANALYSIS
Process / Biochemical
Process Simulator
 SuperPro Designer
BIOPROCESS DESIGN
PROCESS ECONOMICS
Capital Cost Estimation
Direct fixed capital (DFC)
Working capital
Start-up & Validation costs
Operating Cost Estimation
 Raw materials, labor,
consumables, Lab/QC/QA, Waste
treatment & Disposal, Utilities,
Equipment-dependent Costs,
Miscellaneous
Profitability Analysis
 Gross margin, ROI,
Payback time
Production Plant
1) Citric Acid Production
Production Plant
2) Human Insulin Production
Production Plant
3) Therapeutic Monoclonal
Antibody Production
ANY QUESTIONS
THANK YOU