Development of Sustainable Bioprocesses Modeling and Assessment

by Heinzle, Elmar; Biwer, Arno P.; Cooney, Charles L.

• ISBN13: 9780470015599
• ISBN10: 0470015594
• Edition: 1st
• Format: Hardcover
• Copyright: 2007-01-02
• Publisher: WILEY

Summary

Bioprocess technology involves the combination of living matter (whole organism or enzymes ) with nutrients under laboratory conditions to make a desired product within the pharmaceutical, food, cosmetics, biotechnology, fine chemicals and bulk chemicals sectors. Industry is under increasing pressure to develop new processes that are both environmentally friendly and cost-effective, and this can be achieved by taking a fresh look at process development; - namely by combining modern process modeling techniques with sustainability assessment methods. Development of Sustainable Bioprocesses: Modeling and Assessment describes methodologies and supporting case studies for the evolution and implementation of sustainable bioprocesses. Practical and industry-focused, the book begins with an introduction to the bioprocess industries and development procedures. Bioprocesses and bioproducts are then introduced, together with a description of the unit operations involved. Modeling procedures, a key feature of the book, are covered in chapter 3 prior to an overview of the key sustainability assessment methods in use (environmental, economic and societal). The second part of the book is devoted to case studies, which cover the development of bioprocesses in the pharmaceutical, food, fine chemicals, cosmetics and bulk chemicals industries. Some selected case studies include: citric acid, biopolymers, antibiotics, biopharmaceuticals. An accompanying CD-ROM will provide readers with hands-on materials so that the techniques can be put into practice. These materials include a demo version of SuperPro Designer software (used in process engineering) and models of all featured case studies, excel sheets of assessment methods, Monte Carlo simulations and exercises.

Author Biography

Professor Elmar Heinzle, Universität des Saarlandes, Germany

Dr. Charles Cooney, MIT, USA

Both internationally-recognised experts in biochemical engineering and modeling

Dr Arno Biwer, MIT/ Universität des Saarlandes, Germany

Table of Contents

Preface	xiii
Acknowledgments	xvii
List of Contributors	xix
PART I THEORETICAL INTRODUCTION
1 Introduction	3
1.1 Bioprocesses	3
1.1.1 History of Biotechnology and Today's Situation	3
1.1.2 Future Perspectives	6
1.2 Modeling and Assessment in Process Development	7
2 Development of Bioprocesses	11
2.1 Types of Bioprocess and Bioproduct	11
2.1.1 Biocatalysts and Process Types	11
2.1.2 Raw Materials	17
2.1.3 Bioproducts	20
2.2 Bioreaction Stoichiometry, Thermodynamics, and Kinetics	23
2.2.1 Stoichiometry	23
2.2.2 Thermodynamics	28
2.2.3 Kinetics	29
2.3 Elements of Bioprocesses (Unit Operations and Unit Procedures)	32
2.3.1 Upstream Processing	33
2.3.2 Bioreactor	36
2.3.3 Downstream Processing	40
2.3.4 Waste Treatment, Reduction and Recycling	50
2.4 The Development Process	52
2.4.1 Introduction	52
2.4.2 Development Steps and Participants	53
3 Modeling and Simulation of Bioprocesses	61
3.1 Problem Structuring, Process Analysis, and Process Scheme	62
3.1.1 Model Boundaries and General Structure	62
3.1.2 Modeling Steps	63
3.2 Implementation and Simulation	66
3.2.1 Spreadsheet Model	66
3.2.2 Modeling using a Process Simulator	66
3.3 Uncertainty Analysis	71
4 Sustainability Assessment	81
4.1 Sustainability	81
4.2 Economic Assessment	82
4.2.1 Capital-Cost Estimation	83
4.2.2 Operating-Cost Estimation	88
4.2.3 Profitability Assessment	94
4.3 Environmental Assessment	95
4.3.1 Introduction	95
4.3.2 Structure of the Method	96
4.3.3 Impact Categories and Groups	99
4.3.4 Calculation of Environmental Factors	103
4.3.5 Calculation of Indices	105
4.3.6 Example Cleavage of Penicillin G	105
4.4 Assessing Social Aspects	107
4.4.1 Introduction	107
4.4.2 Indicators for Social Assessment	108
4.5 Interactions between the Different Sustainability Dimensions	112
PART II BIOPROCESS CASE STUDIES
Introduction to Case Studies	121
5 Citric Acid – Alternative Process using Starch	125
5.1 Introduction	125
5.2 Fermentation Model	125
5.3 Process Model	128
5.4 Inventory Analysis	130
5.5 Environmental Assessment	132
5.6 Economic Assessment	134
5.7 Conclusions	135
6 Pyruvic Acid – Fermentation with Alternative Downstream Processes	137
6.1 Introduction	137
6.2 Fermentation Model	137
6.3 Process Model	138
6.3.1 Bioreaction and Upstream	138
6.3.2 Downstream Processing	141
6.4 Inventory Analysis	142
6.5 Environmental Assessment	144
6.6 Economic Assessment	145
6.7 Conclusions	145
7 L-Lysine – Coupling of Bioreaction and Process Model	155
Arnd Knoll, Jochen Buechs
7.1 Introduction	155
7.2 Basic Strategy	156
7.3 Bioreaction Model	156
7.4 Process Model	159
7.5 Coupling of Bioreaction and Process Model	162
7.5.1 Assumptions	163
7.6 Results and Discussion	164
8 Riboflavin – Vitamin B2	169
Wilfried Storhas, Rolf Metz
8.1 Introduction	169
8.2 Biosynthesis and Fermentation	170
8.3 Production Process and Process Model	171
8.3.1 Upstream Processing	172
8.3.2 Fermentation	174
8.3.3 Downstream Processing	174
8.4 Inventory Analysis	174
8.5 Ecological Assessment	175
8.6 Economic Assessment	176
8.7 Discussion and Concluding Remarks	177
9 α-Cyclodextrin	181
9.1 Introduction	181
9.2 Reaction Model	182
9.3 Process Model	182
9.3.1 Solvent Process	182
9.3.2 Non-solvent Process	184
9.4 Inventory Analysis	185
9.5 Environmental Assessment	186
9.6 Economic Assessment	186
9.7 Conclusions	189
10 Penicillin V	193
10.1 Introduction	193
10.2 Modeling Base Case	193
10.2.1 Fermentation Model	193
10.2.2 Process Model	194
10.3 Inventory Analysis	196
10.4 Environmental Assessment	197
10.5 Economic Assessment	197
10.6 Monte Carlo Simulations	198
10.6.1 Objective Functions, Variables, and Probability Distributions	198
10.6.2 Results	201
10.7 Conclusions	206
11 Recombinant Human Serum Albumin	211
M. Abdul Kholiq, Elmar Heinzle
11.1 Introduction	211
11.2 Bioreaction Model	212
11.2.1 Stoichiometry	212
11.2.2 Multi-stage Fermentation and Feeding Plan	213
11.2.3 Total Broth Volume in Production Scale and Raw Material Consumption	214
11.3 Process Model	215
11.3.1 Bioreaction	215
11.3.2 Downstream Processing	215
11.4 Economic Assessment	218
11.5 Ecological Assessment	219
11.6 Conclusions	221
12 Recombinant Human Insulin	225
Demetri Petrides
12.1 Introduction	225
12.1.1 Two-chain Method	226
12.1.2 Proinsulin Method	226
12.2 Market Analysis and Design Basis	226
12.2.1 Process Description	227
12.2.2 Inventory Analysis and Environmental Assessment	233
12.2.3 Production Scheduling	234
12.3 Economic Assessment	235
12.4 Throughput-Increase Options	237
12.5 Conclusions	238
13 Monoclonal Antibodies	241
13.1 Introduction	241
13.2 Process Model	241
13.3 Inventory Analysis	243
13.4 Economic Assessment	245
13.5 Environmental Assessment	246
13.6 Uncertainty Analysis	247
13.6.1 Scenarios	247
13.6.2 Sensitivity Analysis	248
13.6.3 Monte Carlo Simulations	249
13.7 Conclusions	255
14 α-1-Antitrypsin from Transgenic Plant Cell Suspension Cultures	261
Elizabeth Zapalac, Karen McDonald
14.1 Introduction	261
14.2 Process Description	263
14.3 Model Description	263
14.4 Discussion	265
14.5 Conclusions	268
15 Plasmid DNA	271
Sindélia S. Freitas, José A.L. Santos, D. Miguel F. Prazeres
15.1 Introduction	271
15.1.1 General	271
15.1.2 Case Introduction	272
15.1.3 Process Description	272
15.2 Model Description	275
15.2.1 Bioreaction Section	275
15.2.2 Downstream Sections	276
15.3 Inventory Analysis	277
15.4 Economic Assessment	278
15.5 Environmental Assessment	281
15.6 Discussion	282
15.7 Conclusions	283
Index	287