Introduction on Scale UpIntroduction on Scale UpFine Chemicals : Fine Chemicals :

From Lab to Plant SiteFrom Lab to Plant Site

ByByWiratni, PhDWiratni, PhD

Gadjah Mada UniversityGadjah Mada UniversityYogyakarta - IndonesiaYogyakarta - Indonesia

Evolution of chemical engineeringEvolution of chemical engineering

Global trend in chemical industries

Mass production Specialties/fine chemicalsFocused on CONVERSION Emphasized on PROPERTIES

‘Conventional’Chemical Engineering

New view in chemical engineering:Product Engineering

Chemical industries in developing Chemical industries in developing countriescountries

DESIGNERS PROCESSENGINEERS

LICENCES

OPERATIONS

NET PROFIT

Flexibility for changesFlexibility for changesInternationalchemical giants(DuPont, BASF, Dow)

Chemicalplantsin developing countries

Natural resources

Commoditization

Specialties

LICENSE!

STRONG R & D

Rawmaterials

Crudeproducts

Finechemicals

Price scale

Chemicalengineering

Productengineering

Position of BiotechnologyPosition of Biotechnology

Highly specific in producing particular Highly specific in producing particular compounds compounds important role in fine important role in fine chemical productionchemical production

Characteristics:Characteristics:

- higher level of uncertainty- higher level of uncertainty

- decreasing performance of - decreasing performance of microorganismsmicroorganisms

Bioprocess EngineeringBioprocess Engineering

BIOREACTOR

Raw material (substrate)

Microorganism/enzyme

PURIFICATIONUNITS

FermentationBroth

Product

WASTE

DOWNSTREAMPROCESSING

Downstream processingDownstream processing

Very costly; can take up to 70% of total Very costly; can take up to 70% of total investmentinvestment

Very important in bioprocess as it Very important in bioprocess as it determines the specification of product determines the specification of product (purity, physical/chemical characteristics, (purity, physical/chemical characteristics, etc.)etc.)

Example of BioproductExample of Bioproduct

Poly-Poly--Hydroxy-Butirate (PHB):-Hydroxy-Butirate (PHB):

Biodegradable polymer with high Biodegradable polymer with high biocompatibility for medical purposesbiocompatibility for medical purposes

Produced intracellularly by Produced intracellularly by microorganisms (e.g. microorganisms (e.g. Alcaligenes Alcaligenes euthrophuseuthrophus), using sugar compounds as ), using sugar compounds as substratesubstrate

Nature of PHBNature of PHB

Characteristics:Characteristics:Amount of PHB Amount of PHB accumulatedaccumulatedDegree of crystallinityDegree of crystallinityPhysical/mechanical Physical/mechanical propertiespropertiesPurityPurity

VERY SENSITIVE TO VERY SENSITIVE TO PROCESS CONDITIONSPROCESS CONDITIONS

ProblemsProblems

PHB is carbon storage for the PHB is carbon storage for the microorganisms: they will accumulate it microorganisms: they will accumulate it when they have plenty of food, and will when they have plenty of food, and will consume it when they are lack of foodconsume it when they are lack of food

Must determine:Must determine:

When is the optimum harvesting time??When is the optimum harvesting time??

ProblemsProblems

PHB is biodegradable, and so it is susceptible to PHB is biodegradable, and so it is susceptible to oxidation, chlorination, etc. that may lead to oxidation, chlorination, etc. that may lead to decreasing molecular weight.decreasing molecular weight.

Must determine:Must determine:

What chemicals to be used in purification What chemicals to be used in purification process?process?

What temperature does not destructive to PHB?What temperature does not destructive to PHB?

ProblemsProblems

If the previous questions have been answered If the previous questions have been answered through laboratory experiments, you may define through laboratory experiments, you may define optimum conditions (composition of substrate, optimum conditions (composition of substrate, temperature, pH, etc) for PHB production.temperature, pH, etc) for PHB production.

Bigger problem:Bigger problem:

Do those optimum conditions for Erlenmeyer Do those optimum conditions for Erlenmeyer flask still hold for 100 L fermentor?flask still hold for 100 L fermentor?

Menghitung kebutuhan powerMenghitung kebutuhan power

Power number

Reynold number

Example: Making homogeneous Example: Making homogeneous solutionssolutions

LAB SCALECOMMERCIAL SCALE

(IDEAL) (NON-IDEAL)

Why studying scale-up Why studying scale-up techniques?techniques?

Producing Fine ChemicalsProducing Fine Chemicals

The technology is not matured yetThe technology is not matured yetVery specific for each particular productVery specific for each particular productVery costly if buy licensed technology for Very costly if buy licensed technology for

each producteach productCompanies must have very strong R&D Companies must have very strong R&D

with two fold tasks:with two fold tasks:1. developing new products1. developing new products2. designing commercial units 2. designing commercial units (SCALE-(SCALE-UP)UP)

Scale Up in Essential Oil Scale Up in Essential Oil ProductionProduction

Laboratoryexperiment

Pilot scale Commercial scale

SCALE UP PROCESS

Route to CommercializationRoute to CommercializationLABORATORY

SCALE

MATHEMATICALMODELS

TRIALAND

ERROR

VERIFICATION INPILOT PLANT

COMMERCIAL PRODUCTION

ERRORS