Development of Sustainable Bioprocesses

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.

Supplementary material provides 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.

Previously available on CD-ROM, the supplementary material can now be accessed via http://booksupport.wiley.com by entering the author name, book title or isbn and clicking on the desired entry. This will then give a listing of all the content available for download. Please read any text files before downloading material.

Preface.

Acknowledgements.

List of Contributors.

Part I: Theoretical Introduction.

1. Introduction.

1.1. Bioprocesses.

1.2. Modeling and Assessment in Process Development.

2. Development of Bioprocesses.

2.1. Types of Bioprocesses and Bioproducts.

2.2. Bioreaction Stoichiometry, Thermodynamics and Kinetics.

2.3. Elements of Bioprocesses (Unit Operations and Unit Processes).

2.4. The Development Process.

3. Modeling and Simulation of Bioprocesses.

3.1. Problem Structuring, Process Analysis and Process Scheme.

3.2. Implementation and Simulation.

3.3. Uncertainty Analysis.

4. Sustainability Assessment.

4.1. Sustainability.

4.2. Economic Assessment.

4.3. Environmental Assessment.

4.4. Assessing Social Aspects.

4.5. Interactions Between the Sustainability Dimensions.

Part II: Bioprocess Case Studies.

Introduction to Case Studies

5. Citric Acid - Alternative Process Using Starch.

5.1. Introduction.

5.2. Fermentation Model.

5.3. Process Model.

5.4. Inventory Analysis.

5.5. Environmental Assessment.

5.6. Economic Assessment.

5.7. Conclusions.

6. Pyruvic Acid - Fermentation with Alternative Downstream Processes.

6.1. Introduction.

6.2. Fermentation Model.

6.3. Process Model.

6.4. Inventory Analysis.

6.5. Environmental Assessment.

6.6. Economic Assessment.

6.7. Conclusions.

7. L-Lysine - Coupling of Bioreaction and Process Model.

7.1. Introduction.

7.2. Basic Strategy.

7.3. Bioreaction Model.

7.4. Process Model.

7.5. Coupling of Bioreaction and Process Model.

7.6. Results and Discussion.

8. Riboflavin – Vitamin B₂.

8.1. Introduction.

8.2. Biosynthesis and Fermentation.

8.3. Production Process and Process Model.

8.4. Inventory Analysis.

8.5 Ecological Assessment.

8.6 Economic Assessment.

8.7 Discussion and Concluding Remarks.

9. α-Cyclodextrin.

9.1. Introduction.

9.2. Reaction Model.

9.3. Process Model.

9.4. Inventory Analysis.

9.5. Environmental Assessment.

9.6. Economic Assessment.

9.7. Conclusions.

10. Penicillin V.

10.1. Introduction.

10.2. Modeling Base Case.

10.3. Inventory Analysis.

10.4. Environmental Assessment.

10.5. Economic Assessment.

10.6. Monte Carlo Simulations.

10.7. Conclusions.

11. Recombinant Human Serum Albumin.

11.1. Introduction.

11.2. Bioreaction Model.

11.3. Process Model.

11.4. Economic Assessment.

11.5. Ecological Assessment.

11.6. Conclusions.

12. Recombinant Human Insulin.

12.1. Introduction.

12.2. Market Analysis and Design Basis.

12.3. Economic Assessment.

12.4. Throughput Increase Options.

12.5. Conclusions.

13. Monoclonal Antibodies.

13.1. Introduction.

13.2. Process Model.

13.3. Inventory Analysis.

13.4. Economic Assessment.

13.5. Environmental Assessment.

13.6. Uncertainty Analysis.

13.6. Conclusions.

14. α-1-Antitrypsin from Transgenic Plant Cell Suspension Cultures.

14.1. Introduction.

14.2. Process Description.

14.3. Model Description.

14.4. Discussion.

14.5 Conclusions.

15. Plasmid DNA.

15.1. Introduction.

15.2. Model Description.

15.3. Inventory Analysis.

15.4. Economic Assessment.

15.5. Environmental Assessment.

15.6. Discussion.

15.7. Conclusions.

Index.

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

This book provides a framework for the development of sustainable bioprocesses. It includes methods for modeling and assessing both the economic and environmental aspects of biotechnological processes and illustrates their application in a series of case studies covering a broad range of products.

The book:

• provides, in four chapters, an introduction to bioproducts and bioprocesses and the unit operations involved in manufacturing, as well as bioprocess modeling in combination with economic and environmental assessment methods;
• cuts across multiple process industries, including pharmaceutical, biochemicals, chemicals and food production;
• addresses risk and uncertainty analysis which are particularly important in early process and product development;
• presents a unique set of case examples from various parts of biotechnology that improve the understanding of this technology and provide a starting point for developing a specific model.

The CD-ROM included contains the process models described in the text. All process model examples are implemented into SuperPro Designer ä. The models are selected as characteristic examples of major bioprocess applications including bulk bio-chemicals, fine chemicals, enzymes, low and high molecular weight pharmaceuticals. Topics covered are: Citric Acid, Pyruvic Acid, L-Lysine, Riboflavin – Vitamin B2, α-Cyclodextrin, Penicillin V, Recombinant Human Serum Albumin, Recombinant Human Insulin; Monoclonal Antibodies, α-1-Antitrypsin from Transgenic Plant Cell Suspension Cultures and Plasmid DNA production. These examples provide a hands-on-approach, which will be useful to both students and professionals already working in bioprocess industries.

This book provides an integrating framework for the student in chemical and biochemical engineering and the scientist and engineer engaged in process development working in the biochemical, chemical and process industries, as well as biologists, chemists, environmental managers and business economists.

The authors acknowledge the sponsorship of the Deutsche Bundesstiftung Umwelt, Osnabrück, Germany.