Basic Flowsheeting in Biological Processes PDF

BASIC FLOWSHEETING IN BIOLOGICAL PROCESS  PROJECT INTRODUCTION Basic flowsheeting, or process flow diagrams (PFDs), are essential tools in process engineering that provide a visual representation of...

BASIC FLOWSHEETING IN BIOLOGICAL PROCESS  PROJECT INTRODUCTION Basic flowsheeting, or process flow diagrams (PFDs), are essential tools in process engineering that provide a visual representation of the flow of processes and equipment within a plant. These diagrams focus on the relationships among major equipment, aiding in the understanding and optimization of processes, particularly in both chemical and biological engineering. In biological processes, flowsheeting incorporates additional considerations such as microbial kinetics, sterilization, and downstream processing, distinguishing it from traditional chemical processes. Reference: N. Metta et al., “Dynamic Flowsheet Model Development and Sensitivity Analysis of a Continuous Pharmaceutical Tablet Manufacturing Process Using the Wet Granulation Route,” Processes, vol. 7, no. 4, p. 234, Apr. 2019, doi: https://doi.org/10.3390/pr7040234. “Process Flow Sheet Generation & Design through a Group Contribution Approach d’Anterroches, Loïc.” Accessed: Aug. 27, 2024. [Online]. Available: https://backend.orbit.dtu.dk/ws/portalfiles/portal/5067161/PEC05-54.pdf OUTLINE FUNDAMENTALS APPLICATIONS TOOLS AND SOFTWARES  FUNDAMENTALS: FLOWSHEET A flowsheet is a graphical representation of a whole process, wherein its components are mainly the raw material, the energy and material balances that flow in and out of the varying process units, the final product, pipes, and the equipments carrying out those processes. Commonly found in the setting of an industrial scale operation, so it is important for the engineers involved to optimize such processes for efficiency.  FUNDAMENTALS: FLOWSHEET The key differences between biological process and chemical process. As for biological processes, they utilize living microbial organisms such as, bacterias, enzymes, and fungis. The reactions involved in processes are specific to certain parameters such as temperature, pressure, and the pH level. Lastly, their use of microbial organisms makes them relatively better for the environment compared to a chemical process. As for biological processes, they utilize living chemical reagents such as, acid and bases. The reactions involved in processes are less specific, or basically have a wider range of the certain parameters such as temperature, pressure, and the pH level. The wider range of those parameters has led to unwanted by-products at times. These unwanted by-products could potentially be harmful to the environment should they not be disposed of properly.  FUNDAMENTALS: FLOWSHEET Block Flow Diagrams (BFD) are the simplest form of flowsheet, wherein the simplicity allows for it to be an overview of a complex process. The blocks represent an equipment or a process. The energy and material flows are represented with an arrow, and that it starts with a raw material and ends with a product. This is a block flow diagram of the continuous extractive alcoholic fermentation, as a mixture of glucose and xylose was continually fed to a bioreactor containing Pichia stipitis as the microbial organism whose sole purpose is to ferment in order to produce bio-ethanol.  FUNDAMENTALS: FLOWSHEET Process Flow Diagrams (PFD) are the more detailed version of a Block Flow Diagram, generated by process simulation softwares such as ASPEN, and DWSIM. The process flow streams are basically numbered, while the equipments follow a certain nomenclature (Barghout and Qiao, 2020): First letter: equipment (P = pump) First number: plant section (1 = section 1 of plant) Last numbers: equipment number (01 = pump 1 in this section) Last letters: show duplicates/triplicates when two or more of the same equipment is used for the same stage of the process.  FUNDAMENTALS: COMPONENTS Equipments in the flowsheet are easily distinguished since they come in various forms  FUNDAMENTALS: COMPONENTS Heat Exchangers - transfers heat between two fluids separated by a series of pipes. In biological processes, it regulates the temperature within the bioreactor Reactors - it is an environment configured with the optimal parameters to allow for the biological reactions like fermentation, or the reactions of enzymes to take place. Pressure changers - it regulates the pressure as biological processes are particularly sensitive with that parameter  FUNDAMENTALS: COMPONENTS Distillation column - this exploits the difference of boiling point wherein the less volatile component is purified at the bottom, while the more volatile component is recovered at the top. Mixers - for biological processes, it ensures that the microbial organisms are well distributed throughout the process. Pipes - the most essential of them all, as it is an enclosed cylinder wherein the materials for processing are transported from one equipment to another.  FUNDAMENTALS: ROLE IN PROCESS DESIGN Biological processes are really complex processes or reactions that are often modelled or simplified by the understanding of kinetics Through the use of flowsheeting, production process design using biological systems can be optimized through the use of visuals and computer-aided calculations and simulations These optimizations and calculations are necessary to create feasible production processes of certain biological products such as food, liquor, pharmaceuticals, and others.  FUNDAMENTALS: ANALYSIS Material balances are based on the conservation of mass, stating that in steady-state MATERIAL BALANCES processes, mass entering a system equals mass leaving it. This principle helps calculate unknowns, like reactant needs and product yield and applies to atoms, molecules, and total mass. System and Process Types: Systems can be open (allowing mass exchange) or closed (no exchange). Processes include batch (closed), semi-batch (input or output allowed), fed-batch (input only), and continuous (both input and output). Steady State vs. Equilibrium: Steady-state maintains constant system properties over time, while equilibrium means no net change. Equilibrium is usually avoided in processing to keep materials transforming. Conservation of Mass: The mass balance equation tracks mass entering and leaving a system, accounting for any chemical reactions.  FUNDAMENTALS: ANALYSIS Energy balances help calculate necessary cooling or heating, essential for processes like ENERGY BALANCES steam sterilization. The principle of energy conservation is key to designing systems that maintain optimal process temperatures. The general energy-balance equation can be expressed as: Energy in through system boundaries−Energy out through system boundaries =Energy accumulated within the system For a process with one input and one output stream, the energy balance is: To simplify, the equation can be written using enthalpy (H), which is defined as: The specific enthalpy (h) is: The general energy-balance equation using enthalpy becomes:  FUNDAMENTALS: ANALYSIS SIZING AND COSTING OF EQUIPMENTS Graphical Estimation Equipment Cost Estimation Using Empirical Costs can also be estimated graphically, where the Equations equipment's capacity (e.g., flow rate in gallons per minute) is plotted against the purchase cost. This method provides a Equipment costs are often calculated using visual approximation but may be less accurate for outdated empirical equations, which generally follow the form: data. Importance of Current Data It is crucial to use up-to-date information for cost Here: estimation. Tools like Aspen, when kept current, can provide Fm​ is the material factor, which can be found in better approximations of equipment costs. However, older tables specific to the equipment type. versions of such tools may reflect outdated pricing, leading S is the sizing factor (e.g., flow rate, capacity). to inaccuracies. a, b, and c are equipment-specific coefficients. Cost Estimation for Other Equipment In the case of a centrifugal pump, the sizing factor S Similar empirical relationships exist for other types of might be defined as: equipment, such as fans and heat exchangers. For a fan, the sizing factor (S) might be simply the flow rate in cubic feet per minute (CFM), and the cost could be estimated using a similar empirical formula with equipment-specific coefficients.  FUNDAMENTALS: ANALYSIS ECONOMIC EVALUATION OPTIMIZATION The economic evaluation of bioprocesses involves the Optimization in the context of biological engineering systematic assessment of both capital investment costs refers to the process of improving the efficiency and (CapEx) and production costs (OpEx). Capital cost-effectiveness of bioprocesses. This involves the investment costs refer to the initial expenditures careful design and selection of unit operations, necessary to establish a bioprocessing facility, which equipment sizing, and cost analysis to reduce both includes acquiring, installing, and operationalizing capital investment and production costs. The goal is to equipment, as well as costs associated with building enhance the overall performance of enzymatic bio- infrastructure. conversions, microbial fermentations, and cell cultures by minimizing resource consumption (such as materials Production costs encompass the ongoing operational and energy) and maximizing output, ultimately leading to expenses required for the bioprocess, including more economical production processes. expenditures on raw materials, energy, labor, equipment usage, and maintenance. Conducting an economic evaluation is crucial for understanding the financial requirements, optimizing cost-efficiency, and ensuring the overall viability of bioprocess operations.  APPLICATIONS ENZYME EXTRACTION AND PURIFICATION PROCESS  APPLICATIONS THE RECOVERY OF CELLULASES FROM COFFEE HUSKS  APPLICATIONS PRODUCTION OF LACCASE AND OTHER ENZYMES FOR THE WOOD INDUSTRY TOOLS AND SOFTWARES MATLAB 01It enables - BRANDING users to perform dynamic modeling of biological systems, the simulation of biological processes, and evaluation of the obtained results through such tools as graphical representations and algorithms. Python One example is PySB, a Python-based modeling framework that generates reaction rules from a Python program. These rules can then be analyzed or used to create equations for simulation in which PySB employs a high-level, action-oriented vocabulary that aligns with the framework. (Lopez et al., 2013). SuperPro Designer It mainly deals with Chemical processes but it can be equally used to model and simulate the biological processes particularly those that involve biochemical reactions and unit operations. SuperPro can also carry out an accurate material and energy balance to keep track of process performance.