crystallizer.ppt
DESCRIPTION
crystalTRANSCRIPT
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CHEE 450: Insulin Design Project
CRYSTALLIZATIONCRYSTALLIZATIONUNITUNIT
CRYSTALLIZATIONCRYSTALLIZATIONUNITUNIT
Rachel Adams
Jana Dengler
Megan MacLeod
Kyla Sask
Rachel Adams
Jana Dengler
Megan MacLeod
Kyla Sask
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CRYSTALLIZATION UNIT
OutlineOutline
• Purpose of Crystallizer• Methods of Crystallization• Design Specifications• Engineering Drawing• Alternative Cost and Suppliers• Alternative Processes• Questions
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CRYSTALLIZATION UNIT
Purpose of CrystallizerPurpose of Crystallizer
• Used to recover pure solids from solution
• Highly desirable end product because of:– Exceptional purity– Ease of handling– Long shelf life
• One of the final treatment steps in the purification and concentration of insulin
• 98% of the insulin must be crystallized
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CRYSTALLIZATION UNIT
Mechanism of CrystallizationMechanism of Crystallization
• Crystal nucleation and amorphous precipitates are in competition during supersaturation conditions
• Nucleation favored by slowly exceeding the equilibrium point of saturation – permits time for the protein structure
to orient in a crystalline lattice
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CRYSTALLIZATION UNIT
Continuous or Batch DesignContinuous or Batch Design
• Benefits of Continuous– Can maintain solution in supersaturated state– Large fluidized bed for crystallization – Minimizes operation costs– Minimize down time (startup and shutdown)
• Benefits of Batch– Good when have low concentration of product, high
viscosity or many impurities– Can produce high quality crystal
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CRYSTALLIZATION UNIT
Methods of CrystallizationMethods of Crystallization
• Supersaturation: liquid (solvent) contains more dissolved solids (solute) than can ordinarily be accommodated at that temperature
• Can be achieved by several methods:– Cooling– Evaporation– Solvent addition– Precipitant Addition
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CRYSTALLIZATION UNIT
Cooling MethodCooling Method
• Concentrated solution gradually cooled below saturation temperature (50-60°C) to generate a supersaturated state
• Yields well defined micron-sized crystals
• Shell and tube heat exchanger is used to cool solution
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CRYSTALLIZATION UNIT
Cooling MethodCooling Method
• Advantages: – High purity downstream
• Disadvantages:– Temperature change does not always have a positive
effect on supersaturation in proteins– Protein stability may be at risk– Solubility can be relatively insensitive to temperature
at high salt concentrations– Cooling will only help reach supersaturation in
systems where solubility and temperature are directly related
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CRYSTALLIZATION UNIT
Evaporation MethodEvaporation Method
• Solute dissolves in solution when heated to a certain temperature (75°C)
• Slowly cooled until crystals precipitate• Shell and tube heat exchanger is used to heat
and cool solution
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CRYSTALLIZATION UNIT
Evaporation MethodEvaporation Method
• Advantages: – high purity levels downstream
• Disadvantages:– Vaporization chamber requires high pressures– Protein viability very sensitive to high
temperatures
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CRYSTALLIZATION UNIT
Solvent MethodSolvent Method
• Solvents are generally good protein precipitants
• Their low dielectric constants lower the solvating power of their aqueous solutions
• Requires acidic solvent– For crystallization, an insulin protein falls
out of solution at isoelectric point pH 5.4-5.7
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CRYSTALLIZATION UNIT
Solvent MethodSolvent Method
• Advantages:– Proteins viability not at risk due to
temperature change
• Disadvantages:– Possible protein contamination due to
insufficient downstream solvent recovery
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CRYSTALLIZATION UNIT
Addition of Zinc Ions Addition of Zinc Ions
• In the presence of zinc ions, insulin proteins orient to form hexamer structures
• Zinc ions render insulin insoluble which results in micro-crystallization and precipitation
Human Insulin Hexamer with Zinc ion
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CRYSTALLIZATION UNIT
Seeding TechniquesSeeding Techniques
• Primary nucleation is the first step in crystallization - growth of a new crystal – Can bypass primary nucleation (creation of
new crystals) by "seeding" the solution
• Secondary nucleation is crystal growth initiated by contact– Accelerated by "seeding" adding existing
insulin crystals to perpetuate crystal growth
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Progression of CrystallizationProgression of Crystallization
http://www.cheresources.com/cryst.shtml
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CRYSTALLIZATION UNIT
Crystal Size and Growth RateCrystal Size and Growth Rate
• Crystal size distribution is important for the production process; affects:– downstream processing– solids transport– caking and storage properties of the material
• Correct crystal size vital for economic production• Crystals produced in commercial crystallization
processes are usually small– 30 to 100 um in diameter
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CRYSTALLIZATION UNIT
Crystal Size and Growth RateCrystal Size and Growth Rate
• Assumptions:– Continuous– Constant-volume– Isothermal– Well-mixed
• Relates population density and crystal size
GL
Lk
Lk
v
a
/expnn
M :Mass Crystal
A: AreaCrystal
o
3c
2c
• Mechanism of crystal growth to determine crystal growth
sv
as cc3dt
dL
kkk
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CRYSTALLIZATION UNIT
Crystallizer DesignCrystallizer Design
• Addition of acidic solvent to decrease pH to achieve supersaturation
• Addition of Zinc ions to initiate Insulin precipitation
• Implementing of “seeding” technique • Minimize heat variation to maintain protein
stability• Washing and extensive solvent recovery
downstream
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CRYSTALLIZATION UNIT
Design EquationsDesign Equations
2.5DH
H4
DV
slurry of gravity specific24.6
slurry of qualityVolume
crystals of sg75.0solutio of sg25.0
crystals of sgsolution of sgslurry of gravity Specific
.25quantity/0 crystalquality Slurry
flowratetime retentionquantity Crystal
2
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Proposed DesignProposed Design
Temperature 25 °C
Pressure 1.013 bar
Flowrate 111.842 kg/batch
Volume 0.29 m3
Diameter 0.529 m
Height 1.325 m
Residence Time 23.98 h
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CRYSTALLIZATION UNIT
Engineering DrawingEngineering Drawing
http://sundoc.bibliothek.uni-halle.de/diss-online/04/04H181/prom.pdf
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CRYSTALLIZATION UNIT
Costing EstimatesCosting Estimates
• Three costs involved:– Crystallizer unit– Zinc Chloride Solution and Water– Power Requirements
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CRYSTALLIZATION UNIT
Costing EstimatesCosting Estimates
• Crystallizer Unit www.matche.com
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CRYSTALLIZATION UNIT
Costing EstimatesCosting Estimates
• Crystallizer UnitBatch, Atmospheric Crystallizer
0
10000
20000
30000
40000
50000
60000
70000
80000
0.00
0.15
0.30
0.45
0.61
0.76
0.91
1.06
1.21
1.36
1.52
1.67
1.82
1.97
Size (m3)
Co
st (
US
$)
Carbon Steel Stainless Steel
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CRYSTALLIZATION UNIT
Costing EstimatesCosting Estimates
• Zinc Chloride Solution– Many suppliers– $15.00 - $27.00 for 500g
• Power Requirements– Canadian Hydro: 8.99 cents/kWh (April, 2006)
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CRYSTALLIZATION UNIT
Crystallizer SuppliersCrystallizer Suppliers
• GEA Niro Inc.– Companies in over 50 countries– Copenhagen, Columbia, Germany, USA
GEA Kestner Evaporator/Crystallizer
• Swenson Technology Inc. – Illinois, USA
• HPD Inc.– Illinois, USA
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CRYSTALLIZATION UNIT
Alternative ProcessesAlternative Processes
• For special drug purposes and when a zinc-free product is needed
• Alternative processes that can be used include:– Isoelectric Precipitation– Gel Chromatography– Ultrafiltration
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CRYSTALLIZATION UNIT
Isoelectric PrecipitationIsoelectric Precipitation
• Protein purification procedure that can be used with crystallization or on its own
• The pH of a mixture is adjusted to the pI of the protein to be isolated to selectively minimize its solubility
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CRYSTALLIZATION UNIT
Gel Filtration ChromatographyGel Filtration Chromatography
• Molecules are separated according to their size and shape
• Filtration column is filled with porous beads
• Solution passes through column
• Elution through the gel occurs in order of decreasing molecular masses
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CRYSTALLIZATION UNIT
UltrafiltrationUltrafiltration
• Ultrafiltration used to concentrate macromolecular solutions
• Forced under pressure or by centrifugation through a semipermeable membranous disk
• Solvent and small solutes pass
through the membrane, leaving
behind a more concentrated
macromolecular solution
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CRYSTALLIZATION UNIT
QUESTIONS?