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Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 1
Novasep Process: Advanced Purification Technologies for Bio-Based Chemicals
Frontiers Bio-Refining 2012
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 2
The challenge!
Producing Bio-Based Chemicals
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 3
C5 Sugars
Lignin
C6 Sugars
Pre-Treatment
Extraction Separation
How to Get Pure Fractions
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 4
C6 Sugars
What do you really get?
• End product
• Feed material
• Side products
• Salts
• Proteins
• Biomass
Chemical Catalysis
Fermentation
Enzymatic Catalysis
Producing Bio-Based Chemicals
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 5
• Feed material • Side products • Salts • Proteins • Biomass
What it takes to get pure product!
C6 Sugars
Chemical Catalysis
Fermentation
Enzymatic Catalysis
Advanced
Purification
Bio-Based Chemical
Producing Pure Chemicals
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 6
Company Profile
Biopharma Functional Ingredients
Bio-Industries Food
Ingredients
Recombinant Proteins Vaccines mAbs - ADC Blood Fractionation Biomass Extracts Cell Therapy
Sugar Starch Milk
Polyphenols Anthocyanins FOS Sweeteners
White Biotechnology Organic Acids Amino Acids Antibiotics Vitamins Chemical Polyols
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 7 Novasep Process: Your Purification Specialist for White Biotechnology 7
Membrane filtration • Micro, Ultra, Nanofiltration • Reverse Osmosis • Organic, Mineral Membranes • Clarification and Purification • Concentration
Continuous chromatography • Applexion® SSMB, Sequential Simulated Moving Bed
• DCC Dual Column Chromatography • Separation of fractions • Purification
Adsorption Ion exchange
Membrane filtration
Purity
Biobased Chemicals Purification
Catalytic reaction
Catalytic reaction • Enzymatic hydrolysis • Isomerization
Evaporation Crystallization
Continuous chromatography
Key Unit Operations
Electrodialysis
Electrodialysis • Demineralization • Salt Conversion
Evap/Crystallization • Plate/tubular evaporators • Multiple effect • MVR
Adsorption/IEX • Salt conversion • Demineralization • Decolorization • Batch or Continuous
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 8
Key Unit Operations
Membranes, Chromatography, IEX, Electrodialysis =
Efficient, cost-effective, reliable and scalable technologies
Allowing to reach very high degrees of purity
& relying on the use of various physio-chemical properties : pKa
Molar mass
Hydrogen bounds
Solvatation size
Isoelectric point
Hydrophobic/hydrophilic interactions
Polar/non polar interactions
Molecular Geometry configuration
Seeking to find an optimized and integrated process route,
selected among competitive technologies depending on local conditions,
and applied industrially to obtain products which market prices typically < $3/kg
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 9
Ceramic membranes
Ceramic membranes : KerasepTM Modules
1 to 39 membranes module at pilot scale
Up to 99 membranes modules, industrial
Compact, sanitary design
Applications : Clarification of sugar juice
Clarification of fermentation broths (organic acids…)
Purification of vitamins and enzymes
Proteins recovery from whey
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 10
Organic membranes
Ultrafiltration
• Protein recovery
• Protein / enzyme elimination
Nanofiltration
• Concentration
• Whey / sweetener demineralization
• Salt / Acids decolorization
• Sugar fractionation
Reverse osmosis
• Salts / alcohol concentration
• Process water polishing
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 11
Ion Exchange and Adsorption
Batch and continuous ion exchange :
Adsorption on resins and activated carbon
Applications: decolorization, desalting, purification and salt conversion
IEX : Cyclic behavior operated in columns
LOADING STRIPPING REGENERANT
DISPLACEMENT
Feed
Exhausted
Solution
H2O
Back to
Feed
Regenerant
Recovered
Products
H2O
Recovered
Regenerant
FEED DISPLACEMENT
-SO3-,Na+
-CH2-N+(CH3)3,Cl-
O, Na+
CH2-P-O, Na+
- CH2- NI
H
O
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 12
From IEX to continuous IEX
CIEX
Resin is used at its maximum capacity
Fully loaded, ready to be eluted
Partially loaded, and ready to be fully loaded
Loading
Not yet fully loaded, ready to be loaded
Batch IEX
Resin is NOT used at its maximum capacity
Loading
Top layer fully loaded, waiting to be eluted
Partially loaded
Lower layer not loaded
Higher productivity Less resin In-line water and regenerant recycling
Applications of CIEX : Amino-acid (lysine) Organic acids conversion Demineralization Wine tartric acid stabilization…
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 13
Batch Chromatography Principle
Low pressure liquid chromatography allows to separate two components by using their difference of affinity with a solid adsorbent phase (generally ion-exchange resins). No regeneration is required.
Two fractions are recovered : Raffinate (low affinity) & Extract (high affinity)
Example of butane-diol / salt separation
by batch chromatography at 65°C
(BDO boiling point : 235°C)
0
50
100
150
200
250
300
350
400
450
500
0 1000 2000 3000 4000 5000Time (s)
Bu
tan
e-d
iol (g
/L)
-2
0
2
4
6
8
10
12
14
16C
on
du
cti
vit
y (
mS
/cm
)
BDO Cond
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 14
From batch to continuous chromatography
Principle of Simulated Moving Bed (SMB): Simulation of a counter current flux to separate more easily
the different fractions
Continuous chromatographic process (SSMB): More cells in series Discontinuous injection and recovery of extracts and
raffinate Simulation of a counter current flux by switching injection
and recovering points
Benefits Very high purity and recovery rates High capacity Low water consumption.
elution water
Extract
Raffinate
+ Feed
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 15
Inside SSMB PROCESS
Affinity chromatography: Xylose / Arabinose / Glucose separation Glucose / Mannose Polyols
Ion exclusion: Sugar and salt separation Polyol demineralization
Size exclusion :
Polymers separation
Oligosaccharides purification
High purity fractions Low water usage No chemical consumption
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 16
Electrodialysis
ED: transport salts from one solution through an ion exchange
membrane to another solution due to an electrical current
EDBM : Bipolar Membrane Electrodialysis : water splitting used for
salt conversion into acid and base
Applications: desalting and purification of sugars, lactose (typical
industrial unit : 50 kT/y) , organic acids
High desalting efficiency No effluent generation No chemical consumption
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 17
Example 1 : Chemical Polyol Purification
Separation of chemical polyol (Teb > 280’C) and salts by SSMB through an ion exclusion principle, at 65’C
Capacity : 20 kT / y
Concentration by reverse osmosis
Separation at 65’C of chemical polyol and sugar by Applexion® SSMB, on affinity principle : recovery of both non-damaged streams
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 18
Example 2: Lysine Production
Water Water
Lysine
H2SO4 Effluent
1
Effluent
2
NH3
Lysine Water
1 2 3 4 5 6 7 8 9
Lysine Displ.
1
Lysine Displ.
2
Lysine Ads.
Lysine Pre-Ads
2
Lysine Pre-Ads
1
Water Displ.
NH3
Displ.
Elution 2
Elution 1
Lysine : essential amino-acid
Solubility : 642 g/L in water in 20°C
Boiling Point: 312’C (760 mmHg)
Selective extraction from the fermentation broth by continuous ion-exchange
Operating temperature : 55’C
> 99.8 % capture rate achievable
Market price : $1.4 / kg
Installed capacity by Novasep Process : 200 kT/y
polymerization
1,5 - Pentane-di-amine
Bio-based nylon
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 19
Example 3 : Separation of organic acids
Gluconic acid (monoacid) pKa = 3.86 Molar Mass : 196 Da Boiling Point: 674 ‘C at 760 mmHg
Saccharic acid (diacid) pKa = 2.99 – 5 Molar Mass : 210 Da
Boiling Point: 766’C (760 mmHg)
0
5
10
15
20
0,0 1,0 2,0 3,0 4,0 bV
Co
ncen
trati
on
(g
/L)
0
20
40
60
80
100
Pu
rity
sacch
ari
c (
%)
gluconic saccharic % purity saccharic
Intermediate for further
chemical transformation
Target capacity (1 unit ): 200 kT / y
Separation of the two acids by low-pressure chromatography, applied at ambient T’C and with no mineral salt addition
> 99% purity achievable (not possible by direct crystallization)
Direct recycling of gluconic stream without crystallization
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 20
Example 4 : Fatty acids separation
Complementarity of distillation and chromatography for
fatty acids separation / purification
Example of DHA (docosahexaénoïc acid) C22-6 (Omega 3)
to be separated from C22-2 (Omega 6)
C22-0 C20-4w6
332 g/mol
418°
C22-1w9
366 g/mol
436°
C22-2w6
364 g/mol
439°
C22-6w3
356 g/mol
443°
368 g/mol
387°
Ebullition Temperature (‘C)
•Distillation : Separation based on molecular weights and Teb
•Similar behaviour of Omega 3 and 6
Hydrophobicity / affinity • Chromatography HPLC : Separation based on molecular geometry configuration and affinity with a resin phase
• Easy separation of Omega 3 and 6
C22-0 C20-4w6
332 g/mol
C22-1w9
366 g/mol
C22-2w6
364 g/mol
C22-6w3
356 g/mol
368 g/mol
Low retention High retention
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 21
Example 5: Succinic Acid Purification
Succinic acid is produced by fermentation under its salt form : conversion into acid form (by capturing the counter cation) and purification are needed
The process :
Clarification by Kerasep® membrane filtration
2 different conversion routes, depending on local conditions :
• Applexion® CIEX
• Novasep – Mega® Electrodialysis
Nanofiltration : color removal
1st industrial Bio Succinic Acid plant worldwide started in 2009, with Capacity 3,000 t/year (next scale : 25 kT/year)
Molar mass : 118.09 g mol−1
Boiling point : 235 ’C
Solubility in water : 58 g/L (20 °C)
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 22 22
50 pilots available in Europe, USA and China
30 process development studies / yr commercialized
Methodology
Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 23
Purification of the following…
Lactic Acid
Citric Acid
Gluconic acid
Succinic acid
Itaconic acid
Glucaric acid
Glucose
Mannose
Fructose
Xylose
Arabinose
Oligosaccharides
Sorbitol
Mannitol
1,4 BDO 1,3 PDO
Lysin
MSG
IMP
Threonin
GMP
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