Process’integraon ’for1,3PDO...
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Transcript of Process’integraon ’for1,3PDO...
Luuk van der Wielen (and dr. Marcel O3ens) Department of Biotechnology, Faculty of Applied Sciences
Process integra-on for 1,3 PDO produc-on
Flowshee(ng
Op-on 1: close to reality -‐ US 7919 658 (2011)
[A] cell removal
[B] protein removal
[C] inorganics removal
[D] water removal
[E] organics removal
MARKET
FERMENTER
Gen
eral PDO
step
s
[A] Membranes (microfiltraOon)
[B] Membranes (ultrafiltraOon)
[C] Ion exchange (sorpOon)
EvaporaOon (energy integraOon)
DisOllaOon (energy integraOon)
MARKET
US 7919 658 (2
011)
FERMENTER
Comparing conceptual op-ons
[A] cell removal
[B] protein removal
[C] inorganics removal
[D] water removal
[E] organics removal
MARKET
FERMENTER
Gen
eral PDO
step
s
Membranes (microfiltraOon)
Membranes (ultrafiltraOon)
Ion exclusion (sorpOon)
EvaporaOon (energy integraOon)
-‐-‐-‐
MARKET
US 6 479 716 (2002)
FERMENTER
Full defini-on of a process
2. Stream table
Gives stream composiOon, size, condiOons (T,P) and other derivaOve properOes (eg. enthalpy)
1. Flowsheet
Shows order of equipment, connecOng streams, and condiOons (T,P) of streams
3. Cycle diagram
Indicates when each unit is acOve in batch or hybrid process
This informaOon allows techno-‐economic analysis of a process, and calculaOon of its environmental footprint through life cycle analysis
Not required for our conOnuous PDO
process
From block scheme to flowsheet 1. Draw from leW (in) to right (out), avoid crossing lines 2. Group in secOons (in hundreds: e.g. UPS-‐100, Ferm-‐200, DSP-‐300) 3. Number all streams (per secOon: e.g. 101, 102, ….) 4. Replace unit blocks by appropriate icons (soWware library) 5. Specify condiOons (composiOons, T, P) 6. Set an iniOal cycle diagram for batch and hybrid processes 7. Solve all mass and energy balances 8. Evaluate results by techno-‐economic-‐emission analysis 9. Repeat steps 1-‐8 to opOmize
Example: extrac-on, crystallisa-on and solids recovery
cool crystallizer
crystal slurry
crystal product
centrifuge solvent make-‐up
waste
extractor
feed
recycle stream
cool crystallizer extractor centrifuge
solvent make-‐up waste
crystal product
feed
recycle stream
Let’s convert this back to a block scheme to observe how streams are modified
1. Split factors • The split factor α indicates how a stream is divided • Flow of compound k from unit i to unit j = flow in unit i x α • Example: the extractor (unit I)
recycle stream from centrifuge
to unit II
waste stream
feed streams to process
extractor
α12k
Split factor of compound k from unit I to II
Split factor scheme recycle stream
waste stream
cool crystallizer extractor centrifuge
2. “Conversions” • Conversion of species k into species q through chemical reacOon • AlternaOvely, species k is converted to a different phase • Below: A is converted to P (crystal product)
cool crystallizer
• In matrix form: [A] * m = B
Can be solved with g’s and α’s known: m = [A]-‐1 * B
Mathema-cs (for constant split factors) • Equa-ons for ‘A’ per opera-on
Out = In + Produc-on unit I (extractor): m1A = α31Am3A + g1A + g7A unit II (crystallizer): m2A = α12Am1A
unit III (centrifuge): m3A = α23Am2A
Another example: glycine crystallisa-on solvent make-‐up
dis-lla-on
waste
centrifuge
glycine crystal product
saturated amino acid feed crystal
slurry
solvent recycle
crystallizer
Specifica-ons • Glycine crystal producOon: 2000 ton/year • Feed composiOons: x[0..3] = [x0sat, 0, 1-‐x0sat, 0]
0: glycine 1: glycine crystals 2: water 3: ethanol • Recovery > 95% • Solvent loss <1% • Negligible volaOle contaminants • ‘Salt’ content sufficiently high to prevent azeotrope • No solvent with crystals
• Solubility relaOon of glycine in water and ethanol is logarithmic • Non-‐linear, thus more difficult to solve • Split factors are not constant
… use flowsheeOng soWware to simulate a process
In reality, not all constants are constant
Standard today: flowshee-ng sofware
Intelligen SuperProDesigner: bio-‐specific flowsheeOng tool
AspenTech
Aspen Plus: process plant engineering tool Speedup: dynamic simulaOons
Process Systems Enterprises
gPROMS: dynamic simulaOons
The crystalliza-on process redrawn in SPD
Flowsheet for 1,3 PDO Sec-on structure
FermentaOon secOon 100
ClarificaOon secOon 200
PurificaOon secOon 300
Flowsheet for 1,3 PDO Fermenta-on sec-on -‐ 100
From the fermenter
To the purifica-on sec-on
Water recycle from evapora-on
Flowsheet for 1,3 PDO Clarifica-on sec-on -‐ 200
Water recycle to microfiltra-on
From clarifica-on
Flowsheet for 1,3 PDO Purifica-on sec-on – 300
The full 1,3PDO process
Good luck with the PDO case!