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Design of Membrane Filtration Systems
forBiotechnology Process
Applications
June 19, 2003
AFS Conference 2003, Reno, NV
April 15, 2003 Template 2AFS Conference 2003, Reno, NV
Who is GEA Filtration ?
April 15, 2003 Template 3AFS Conference 2003, Reno, NV
Who is GEA Filtration ?Who is GEA Filtration ?
mg TechnologiesFrankfurt, Germany
mg Engineering mg Chemical
Lurgi AG Lurgi Lentjes AG GEA AGBochum, Germany Zimmer AG
Process Divisions Thermal Divisions
Mech. Separation Process Components Process Engineering Refrigeration Dairy Farm Systems
Strategic Business UnitsFood & Dairy Drying TechnologyChemical Drying technologyPharma EquipmentsEvaporation TechnologyMembrane Filtration Barr RosinDairy, Food & Juice Liquid ProcessingBrewery & BeveragePersonal & Health CareSpare Parts & Service
GEA Filtration
April 15, 2003 Template 4AFS Conference 2003, Reno, NV
What is Biotechnology ?What is Biotechnology ?
Biotechnology ………..
“All lines of work by which products are produced from raw materials with the aid of living things.”
As defined by Karl Ereky, 1917
Biotechnology
April 15, 2003 Template 5AFS Conference 2003, Reno, NV
Biotech Market SegmentsBiotech Market Segments
Food
Pharmaceuticals
Chemical
Bio-pharmaceuticals• Antibiotics• Proteins & peptides• Vaccines• Vitamins
Bio-chemicals• Enzymes• Ethanol• Insecticides &
Pesticides• Poly-lactates
BiotechnologyNutraceuticals• Food
supplements• Health Foods
Bio-food• Wine & Beer• Lactic acid• Citric acid• Flavors &
fragrances
April 15, 2003 Template 6AFS Conference 2003, Reno, NV
Biotechnology ProcessBiotechnology Process
• Microfiltration• Ultrafiltration• Diafiltration
• Precoat Filters
Upstream Processing
• Media Preparation• Fermentation
• Concentration• Ultrafiltration• Diafiltration• Nanofiltration
Cell Harvesting / Clarification
Downstream Processing / Purification
• Cell Rupture • Chromatography
• Centrifugation
April 15, 2003 Template 7AFS Conference 2003, Reno, NV
Typical Biotechnology ApplicationsTypical Biotechnology Applications
Clarification of Fermentation Broths to recover active compoundsCell Harvesting to concentrate and recover whole cells containing productEnzymesAPIs (Active Pharmaceutical Ingredients)Proteins and Amino Acids
April 15, 2003 Template 8AFS Conference 2003, Reno, NV
What is a Membrane Filtration System?
April 15, 2003 Template 9AFS Conference 2003, Reno, NV
Sections of a Membrane Filtration System (Simplified)Sections of a Membrane Filtration System (Simplified)
Permeate
PT
FICFT
Concentrate
Feed
Tank
FT
VSD
FIC
Feed
LT
MembraneMembraneStagesStages
April 15, 2003 Template 10AFS Conference 2003, Reno, NV
Engineering and Design CriteriaEngineering and Design Criteria
Membrane ConfigurationsMembrane Configurations
Conventional ConfigurationsPolymeric Membranes
• Spiral• Tubular & Hollow Fiber• Plate & Frame
Inorganic Membranes• Tubular
Specialized and / or Proprietary Configurations
April 15, 2003 Template 11AFS Conference 2003, Reno, NV
Engineering and Design CriteriaEngineering and Design Criteria
SpiralSpiral--Wound Membrane ElementWound Membrane Element
April 15, 2003 Template 12AFS Conference 2003, Reno, NV
Engineering and Design CriteriaEngineering and Design Criteria
Tubular Polymeric Membrane Elements and ModulesTubular Polymeric Membrane Elements and Modules
Pictures Courtesy of Koch Membrane Systems
April 15, 2003 Template 13AFS Conference 2003, Reno, NV
Engineering and Design CriteriaEngineering and Design Criteria
Ceramic Membrane Elements and ModulesCeramic Membrane Elements and Modules
Pictures Courtesy of TAMI
April 15, 2003 Template 14AFS Conference 2003, Reno, NV
Engineering and Design CriteriaEngineering and Design Criteria
Scepter Membrane Elements and ModulesScepter Membrane Elements and Modules
Pictures Courtesy of Graver Technologies
April 15, 2003 Template 15AFS Conference 2003, Reno, NV
A Few Important Terms & Concepts
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Important TermsImportant Terms
Feed or ProductInitial material into system on feed side of membrane
Retentate or ConcentrateThe fraction of the feed which is rejected by the membrane.
PermeateThe fraction of the feed which passes through the membrane
April 15, 2003 Template 17AFS Conference 2003, Reno, NV
Important TermsImportant Terms
Fluxrate of permeate flow per unit area per unit time“lmh” - liters/square meter/hour“gfd” - gallons/square foot/day
Cross-Flow Rateflow rate of feed material through feed channel or feed side of a membrane element or moduledetermines feed flow characteristics which impacts performance parameters
April 15, 2003 Template 18AFS Conference 2003, Reno, NV
Important TermsImportant Terms
Concentration Factor (“CF”)feed volume (or flow rate) divided by the concentrate volume (or flow rate)
% Rejection100 x ( 1 - [permeate]i / [retentate]i )
April 15, 2003 Template 19AFS Conference 2003, Reno, NV
Important TermsImportant Terms
Pressure Drop (“∆P”)Difference between the inlet and outlet feed-side pressures
Transmembrane Pressure (“TMP”)Difference between feed & permeate pressureDriving force for all membrane filtration processes
Osmotic Pressure (“Π”)Function of MW and component concentrationCounter-pressure which TMP must overcome
April 15, 2003 Template 20AFS Conference 2003, Reno, NV
Membrane Filtration SystemDesign Considerations
AFS Conference 2003, Reno, NV
Steps in the Design ProcessSteps in the Design Process
Review of ApplicationReview of System Design CriteriaPilot TestingEngineering and Design
AFS Conference 2003, Reno, NV
Key Factors of System DesignKey Factors of System Design
Stability of ProductShear SensitivityVolume of Product to be ProcessedUp and Down Stream Operation Steps
AFS Conference 2003, Reno, NV
Steps in the Design ProcessSteps in the Design Process
Review of System Design CriteriaMaterials of ConstructionDesign Specifications
• Food industry Standards “Food Grade”• Dairy Standards 3A• Pharmaceutical / Biotechnology Standards GMP Compliance
Specialized RequirementsXP system
AFS Conference 2003, Reno, NV
GMP Regulatory Compliance RequirementsGMP Regulatory Compliance Requirements
Examples of Validation Documentation (if required)Bill of MaterialsCertificates of Compliance and ConformanceComponent Calibration VerificationMaterial Test ReportsFactory Acceptance Test (FAT)Weld logs, weld maps, etc.
AFS Conference 2003, Reno, NV
Steps in the Design ProcessSteps in the Design Process
Pilot TestingTest on representative feed(s)Validate membrane type and configurationCompilation and review of data
Membrane Configuration SelectionSelection between spiral, ceramic, hollow fiber, cassette, others
AFS Conference 2003, Reno, NV
Engineering and Design CriteriaEngineering and Design Criteria
Membrane Design FactorsType and Material of MembraneConfiguration and Construction of MembraneHousing and Module Design
System Design CriteriaOperating Parameters
• T, P, Flux, CF, DP, TMP, etc.Mode of Operation
• Feed and bleed, batch, etc.System Design
• Stages-in-series, array, etc…Control Scheme
AFS Conference 2003, Reno, NV
Engineering and Design CriteriaEngineering and Design Criteria
Integration of System Design with Plant ProcessCoordination with upstream operations, i.e. fermentersCoordination with downstream operations, i.e. extraction, chromatographic separation, formulation
AFS Conference 2003, Reno, NV
SummarySummary
With proper design and successful integration in the plant’s process, a membrane filtration system can become a key and integral process step within the recovery operation of a biotechnology processor.
April 15, 2003 Template 29AFS Conference 2003, Reno, NV
Americas & Rest of the worldGEA Filtration DivisionNiro Inc.1600 O’Keefe Road Hudson, WI 54016USA+1 715 386 9371 Telephone+1 715 386 9376 [email protected]
Europe, Near & Middle EastDairy, Biotech & PharmaGEA Filtration DivisionGEA Liquid Processing
Scandinavia A/SNorskovvej 1 b8660 SkanderborgDenmark+45 70 15 22 00 Telephone+45 70 15 22 44 [email protected]
Food & Waste WaterGEA Filtration DivisionGEA Wiegand GmbHEinsteinstrasse 9-1576275 EttlingenGermany+49 7243 7050 Telephone+49 7243 7053 30 [email protected]
NZ & AustraliaLiquid Technologies DivisionNiro (NZ) Limited356 Church StreetPenrose, AucklandNew Zealand+64 9 526 3877 Telephone+64 9 526 3873 [email protected]
Liquid Technologies DivisionNiro Australia Pty Limited141 St. Georges RoadN Fitzroy, Victoria3068Australia+61 3 9482 6333 Telephone+61 3 9482 6366 [email protected]
Who is GEA Filtration ?Who is GEA Filtration ?
