Customer Bitop AG, Witten, Germany
Project Simulation of a Heat Integration Network for Chemical Production
Industry Bioengineering, Cosmetics
Solution Type
Process Design and Scale-Up
Plant Design and Optimization
Applied
Software
INOSIM Batch, a predecessor of INOSIM Process Edition.

The software is able to simulate biotechnological reconditioning processes.

  • An integrated hybrid data model emulates the specific requirements of biotechnologically applied substance systems appropriately, providing necessary interfaces to the calculation models.
  • The included library of calculation models contains the following unit operations: split, mix, microfiltration, ultrafiltration, electrodialysis, ion exchange capture, chromatography, cristallization, evaporation, drying, neutralization.
Description of Software Application The customer by biotechnological methods produces an agent (ectoin) for cosmetic production. Before simulation, the process showed high yield losses, big and polluted amounts of effluent and enormous energy consumption.

The causing process steps were simulated with INOSIM Software and then being analyzed stepwise:

  • Yield losses were proved in cases of microfiltration, electrodialysis, and crystallization.
  • As a cause of effluent pollution, unnessecarily high salt addition during microfiltration was identified.
  • Unreasonable energy consumption resulted from complete evaporation of water during solvent change (process step drying).
  • Unnecessarily high amounts of water were proved as well from drying during solvent change.

With the help of simulation, the following procedures were improved and tested:

  • Yield:
    • Three-step instead of one-step microfiltration led to improved ectoine delivery by the bacteria.
    • Analysis of process data led to extended electrodialysis, hence to increased yield.
    • Analysis of mass balances pointed out yield losses with the process step cristallization. Plant retrofit solved that problem.
  • Amount of effluents and salt pollution:
    • Changing microfiltration improved the ratio of yield and water needed. This also reduced the salt pollution of the complete process.

Results:

  • Yield increase by 27 percent
  • Reduction of water by 38 percent
  • Decline of salt pollution by 17 percent
  • Decrease of energy consumption by 16 percent
  • Production costs reduction by 26 percent
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