高效分離純化工藝-面對(duì)發(fā)酵行業(yè)對(duì)化學(xué)品消耗及收課件

EfficientDemineralization–AChallengeForFermentationProducts1EfficientPurification–AChallengeForFermentationProducts高效分離純化工藝-面對(duì)發(fā)酵行業(yè)對(duì)化學(xué)品消耗及收率的挑戰(zhàn)November20122012年11月NovasepProcess:YourPurificationSpecialistforBio-Industries2關(guān)于諾華賽

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NOVASEP2010營(yíng)業(yè)額:3億歐元

(4.18億美元)1200員工,其中研發(fā)人員超過(guò)200人2010revenues:300M€(USD418M)

1200employees,200inR&D每年超過(guò)100個(gè)研發(fā)項(xiàng)目每年生產(chǎn)超過(guò)1000個(gè)活性分子全球有2000余套分離純化系統(tǒng)Over100R&DprojectsperyearOver100activemoleculesproducedperyearOver2,000purificationsystemsinstalledworldwideNovasepProcess:YourPurificationSpecialistforBio-Industries3間歇色譜CHROMATO.蒸發(fā)精餾EVAPO.離子交換IEX膜過(guò)濾MF分離純化PURIFICATION結(jié)晶CRYSTALIZATION連續(xù)色譜SSMB諾華賽：全程分離純化方案提供者

Novasep:PurificationSolutionProvider純度Purity原料制備化學(xué)合成和生物制造BIOMANUFACTURING發(fā)酵細(xì)胞培養(yǎng)危險(xiǎn)化學(xué)品手性化學(xué)品

高能化合物電滲析ED4ProducingbyFermentation挑戰(zhàn)-發(fā)酵產(chǎn)品的分離純化PureProduct純凈產(chǎn)品EfficientDemineralization–AChallengeForFermentationProducts高效脫鹽—針對(duì)發(fā)酵產(chǎn)品的挑戰(zhàn)5Purificationisoftennoteconomical!純化過(guò)程常常不經(jīng)濟(jì)PureProduct純凈產(chǎn)品EfficientDemineralization–AChallengeForFermentationProducts高效脫鹽—針對(duì)發(fā)酵產(chǎn)品的挑戰(zhàn)BatchIEXDemineralization間歇式離交脫鹽Crystallization結(jié)晶HighEffluentGeneration產(chǎn)生大量廢水HighChemicalsConsumption高化學(xué)品消耗MotherLiquor母液LowvalueOutcome低價(jià)值品6Howtoimproveyoureconomics?如何提高經(jīng)濟(jì)性?PureProduct純凈產(chǎn)品EfficientDemineralization–AChallengeForFermentationProducts高效脫鹽—針對(duì)發(fā)酵產(chǎn)品的挑戰(zhàn)BatchIEXDemineralizationCrystallizationHighEffluentGeneration產(chǎn)生大量廢水HighChemicalsConsumption高化學(xué)品消耗MotherLiquor母液LowvalueOutcome低價(jià)值附產(chǎn)品ReduceThese!減少這些!IncreaseThis!提高這個(gè)!ReducingChemicalsConsumption

減少化學(xué)品消耗

EfficientDemineralization–AChallengeForFermentationProducts高效脫鹽—針對(duì)發(fā)酵產(chǎn)品的挑戰(zhàn)7ReducingChemicalsConsumption

減少化學(xué)品消耗Selecttherighttechnology,accordingtoyourlocalconditions!!!根據(jù)實(shí)際工藝狀況,選擇正確的脫鹽技術(shù)BatchIEX間歇離交:

lowsaltloads低含鹽量ContinuousIEX連續(xù)離交: mediumtohighsaltloads中--高含鹽量Electrodialysis電滲析: mediumtohighsaltloads,whenelectricityischeap中--高含鹽量,且電較便宜SSMBChromatography色譜: hightoveryhighsaltloads高--極高含鹽量Whenusingaresinbasedtechnology,selectthemostadaptedresin,onacasetocasebasis!當(dāng)采用基于樹脂的技術(shù)時(shí),需要基于特定的工藝環(huán)境,選擇合適的樹脂工藝：Novasephas200+referencesofresinsinportfolio!諾華賽已有200個(gè)以上個(gè)成功運(yùn)用樹脂的工程案例EfficientDemineralization–AChallengeForFermentationProducts高效脫鹽—針對(duì)發(fā)酵產(chǎn)品的挑戰(zhàn)8DifferentProcessRoutesforOrganicAcids

針對(duì)有機(jī)酸的不同工藝路線EfficientDemineralization–AChallengeForFermentationProducts高效脫鹽—針對(duì)發(fā)酵產(chǎn)品的挑戰(zhàn)9Lysinepurification

案例：賴氨酸連續(xù)離交純化

CONTINUOUS(limitedbuffertanks)生產(chǎn)連續(xù)(緩沖罐減小)Feedandtreatedproduct進(jìn)料罐和處理后產(chǎn)品罐Chemicalsandwaste化學(xué)品儲(chǔ)罐和廢水罐ReuseWatersystem重用水系統(tǒng)BETTERUTILITIESUSAGE公用工程的更好利用Lesschemicals更低的化學(xué)品消耗Lesswater更少的水耗Lesseffluents更少的廢水量LESSDILUTIONDURINGDISPLACEMENT(productorreagent)STEPS置換環(huán)節(jié)減少稀釋(生產(chǎn)或再生)Morestableandhighoutletproductconcentration更穩(wěn)定更高的產(chǎn)品濃度Lesswatertoevaporate更少的蒸發(fā)水量CONTINUOUSPROCESSADVANTAGES連續(xù)處理工藝的優(yōu)勢(shì)ContinuousIonExchangevsDiscontinuous

Principle&Advantages連續(xù)離交與非連續(xù)離交的對(duì)比CONTINUOUSPROCESSLIMITATIONS:連續(xù)處理工藝的局限

Maxlinearvelocityforproperadsorption/Elution吸附/洗脫時(shí)需要更大的線速度Pressuredropconsiderations要注意壓力降因素TypicalMassbalance1System/1PeriodContinuousIonExchangeappliedtolysinepurification連續(xù)離子交換在賴氨酸純化中的應(yīng)用KeyFigures

主要數(shù)據(jù)KeyPerformancesFiguresforContinuousIonExchangeonLysinepurification賴氨酸純化連續(xù)離交系統(tǒng)的主要性能參數(shù)*:Withouttakingintoaccountbackwashingsequence:0,75BV/period.Dependingonpressuredropandsuspendedsolids沒(méi)有計(jì)入反洗水消耗：約0.75BV/周期，根據(jù)壓力降及懸浮物變化

ResinLoading樹脂負(fù)載量180gLys/literresin-MinimumRecovery收率98.5%-MinimumLysineConcentrationinRC

賴氨酸濃度195gLys/L

+/-15g/LLysinecaptureduringadsorption吸附環(huán)節(jié)賴氨酸捕獲率99%Waterconsumption*水耗1,8BV/PeriodH2SO498%consumption98%濃度硫酸消耗<4%Mass/VolumeFeed(i.e.40kg/m3feed)NH3Consumption氨水消耗35gNH3100%/LregeneratedresinNOVASEPSYSTEMFORLYSINE:11CELLSCONTINUOUSPROCESS+1CELLINSPARE

諾華賽設(shè)計(jì)的賴氨酸生產(chǎn)系統(tǒng)：11個(gè)連續(xù)工藝單元+

1個(gè)備用單元ContinuousIonExchangeNovasepdesign賴氨酸連續(xù)離交工業(yè)裝置15

ADVANTAGES

基于SSMB連續(xù)離交的設(shè)計(jì)優(yōu)點(diǎn)MECHANICALDESIGN機(jī)械設(shè)計(jì)NOMOVINGPARTS/STATICCOLUMNS無(wú)移動(dòng)部件COMPACTINLET/OUTLETMULTIPLEPORTVALVESONEACHCOLUMN通過(guò)高度緊湊的多通道自控閥門切換物料MAINTENANCECAPABILITIES/REQUIREMENTS維修維護(hù)POSSIBILITYTOHAVEONECOLUMNOFFCYCLEWITHOUTSTOPPINGTHEPLANTFORGENERALMAINTENANCE,RESINREPLACEMENT…可以在不終正生產(chǎn)的情況下，將任意一個(gè)需要柱子單獨(dú)隔離出來(lái)進(jìn)行維護(hù)、樹脂更換…LESSMAINTENANCEREQUIREMENTS,SIMILARTODISCONTINUOUSPROCESS

更少的維護(hù)要求，在維護(hù)上與間歇工藝相似16PROCESSCONTROL

工藝控制POSSIBILITYWITHOUTANYPIPINGMODIFICATIONTOADJUSTPROCESSZONES(SOFTWAREMODIFICATIONSONLY).能夠在不進(jìn)行任何管道物理連接的情況下，對(duì)各個(gè)柱子的工藝區(qū)進(jìn)行調(diào)整（只是對(duì)自控軟件進(jìn)行設(shè)置）.POSSIBILITYTOPRECISELYMETERALLFLOWSONEACHCOLUMN,FOREACHPROCESSSTEP.

能夠非常精確的對(duì)流經(jīng)每一根離交柱/每一個(gè)子步驟的流量進(jìn)行調(diào)整.4）EXCELLENTDISTRIBUTORSDESIGN卓越的分布器設(shè)計(jì)

Excellentdistributorsquality(Chromatographygrade)–whichguaranteedthebestflowdistributions，andnoresinleakages.色譜分離級(jí)別的分布器，保證無(wú)比均勻的流體分布，杜絕樹脂粉末逃逸現(xiàn)象；.

ADVANTAGES

基于SSMB連續(xù)離交的設(shè)計(jì)優(yōu)點(diǎn)175）EASYPLANTEXPANSIONCAPABILITIES產(chǎn)能擴(kuò)增的靈活性INCREMENTALINCREASEOFPLANTCAPACITYBYADDINGADDITIONALCOLUMNSANDADJUSTPROCESSZONESONTHEWHOLESETOFCOLUMNS在對(duì)系統(tǒng)產(chǎn)能進(jìn)行擴(kuò)增時(shí)，只需要額外增加離交柱，并對(duì)工藝軟件進(jìn)行重新設(shè)置即可；6）FOOTPRINT占地要求的靈活性MOREFOOTPRINTFLEXIBILITY可以根據(jù)客戶現(xiàn)場(chǎng)空間的位置進(jìn)行調(diào)整

ADVANTAGES

基于SSMB連續(xù)離交的設(shè)計(jì)優(yōu)點(diǎn)EfficientDemineralization–AChallengeForFermentationProducts高效脫鹽—針對(duì)發(fā)酵產(chǎn)品的挑戰(zhàn)18SuccinicAcidPurification

案例：丁二酸純化Succinicacidisakeychemicalintermediate丁二酸（琥珀酸）是一種重要的化學(xué)中間體Customer客戶:

JVARD–BioAmberProcessdevelopmentworkstartedin2004工藝開發(fā)工作始于2004年TechnologyScreening技術(shù)篩選ProcessSimulation工藝模擬Processintegration工藝整合Pilotingwork試驗(yàn)工作1stindustrialBioSuccinicAcidplantworldwidestartedin2009,withCapacity3,000t/year全球第一個(gè)發(fā)酵法丁二酸工廠于2009年投產(chǎn)，產(chǎn)能為3000噸/年Otherstudieson-going(morethan6routesstudied)

另外的研發(fā)在繼續(xù)中（超過(guò)6條研發(fā)路線）EfficientDemineralization–AChallengeForFermentationProducts高效脫鹽—針對(duì)發(fā)酵產(chǎn)品的挑戰(zhàn)19SuccinicAcidPurification

丁二酸的純化ClarificationbyKerasep?membranefiltration用Kerasep?

陶瓷膜澄清過(guò)濾2differentprocesses,

dependingonlocalconditions:兩套工藝路線（根據(jù)現(xiàn)場(chǎng)條件）Applexion?CIEX

連續(xù)離交工藝Novasep–Mega?Electrodialysis

電滲析工藝IMPROVEYOURREVENUEFROMMOTHERLIQUOR

從母液中提升收益

EfficientDemineralization–AChallengeForFermentationProducts高效脫鹽—針對(duì)發(fā)酵產(chǎn)品的挑戰(zhàn)20ImproveyourrevenuefromtheMotherLiquor

從母液中尋找收益Becauseofsolubilityequilibrium,MLiscontainingahighamountofyourmainhighvalueproduct!由于維持溶解平衡的原因，致使母液中含有大量高價(jià)值的產(chǎn)品ByusingSSMBChromatography,youcanseparatetheimpuritiesfromthevalueproduct,andrecovertheproduct!通過(guò)使用連續(xù)模擬移動(dòng)床色譜工藝，可以將雜質(zhì)與高品質(zhì)產(chǎn)品分開，提高產(chǎn)品收率。Examples例如CitricacidML:recoveryincreaseupto98,5%,withpurity98%檸檬酸母液：收率上升至98.5%，純度為98%EfficientDemineralization–AChallengeForFermentationProducts高效脫鹽—針對(duì)發(fā)酵產(chǎn)品的挑戰(zhàn)21Membranefiltrationtoclarifybroth陶瓷膜過(guò)濾澄清液體Concentration

濃縮Crystallization結(jié)晶Centrifugestoseparatecrystals離心分離MLChromatographytoseparatethreoninfromremainingnonfermentedsugars,andorganicandmineralimpurities采用色譜技術(shù)分離有機(jī)物及其它雜質(zhì)ThreoninML:recoveryincreasefrom80%to95%+蘇氨酸全程收率：從80%提升至95%以上.ThreoninMotherLiquorPurification案例：蘇氨酸母液純化EfficientDemineralization–AChallengeForFermentationProducts高效脫鹽—針對(duì)發(fā)酵產(chǎn)品的挑戰(zhàn)22Primaryfiltrationtoremovemycelium初級(jí)過(guò)濾去除菌絲體Membranefiltrationtoclarifybroth陶瓷膜過(guò)濾澄清液體Concentration濃縮Chromatographytoseparatecitricacidfromremainingnonfermentedsugars,andorganicandmineralimpurities采用色譜技術(shù)分離檸檬酸及其它雜質(zhì)Polishingbyactivatedcarbonandionexchange活性炭和離子交換精制Evaporation蒸發(fā)Crystallization結(jié)晶CitricAcid–Gypsumfreeprocess

案例：檸檬酸無(wú)石膏生產(chǎn)工藝

EfficientDemineralization–AChallengeForFermentationProducts高效脫鹽—針對(duì)發(fā)酵產(chǎn)品的挑戰(zhàn)23Lesschemicals較少的化學(xué)品消耗Doesnotuselime不使用石灰;a