process optimization for r -pac production
DESCRIPTION
Process Optimization for R -PAC Production. N. Leksawasdi 1 , M. Breuer 2 , B. Hauer 2 , P.L. Rogers 1 , B. Rosche 1. 1 BABS, UNSW, Sydney, NSW, 2052, Australia. 2 BASF-AG, 67056 Ludwigshafen, Germany. What is R-PAC. R-PAC is for R - P henyl- A cetyl- C arbinol. - PowerPoint PPT PresentationTRANSCRIPT
Process Optimization for Process Optimization for RR-PAC -PAC ProductionProduction
N. LeksawasdiN. Leksawasdi11, ,
M. BreuerM. Breuer22, B. Hauer, B. Hauer22, , P.L. RogersP.L. Rogers11, B. Rosche, B. Rosche11
11BABS, UNSW, Sydney, NSW, 2052, AustraliaBABS, UNSW, Sydney, NSW, 2052, Australia
22BASF-AG, 67056 Ludwigshafen, GermanyBASF-AG, 67056 Ludwigshafen, Germany
What is R-PACWhat is R-PAC
R-PAC is for R-Phenyl-Acetyl-Carbinol
Precursor for production of ephedrine & pseudoephedrine; used to treat asthma and flu symptoms
O
O
CH3
H
PDC catalysed reactionsPDC catalysed reactions
PDC
Process of Process of modelmodel development developmentTheoretical for general model structure
Experimental for model structure modification & evaluation of constants
Combined theoretical & experimental
Confirmation of model by independent batch biotranformation profile
Optimization by designing feeding profile for fed batch system
Theoretical model developmentTheoretical model development
Full form
According to King and Altman (1956)
Simplified form
Theoretical modelTheoretical model
ii
iii
i Bkk
Akkkk
k
EBAkkkk
dt
Pd
5
4
32
32
1
32
32
1
ii dt
Pd
dt
Bd
iiii dt
Rd
dt
Qd
dt
Pd
dt
Ad2
iiiri
EAQVdt
Rd iiiriiq
i
EAQVEAVdt
Qd
Product
Reactants
By-products
Experimental model developmentExperimental model development
Enzyme activity
Substrate concentrations
Enzyme deactivation effect
Batch biotransformations for Overall rate of R-PAC formation
Rate constants of by-products formation
Quantification of kinetics
Enzyme activity effectEnzyme activity effect
y = 0.5508x
R2 = 0.9976
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
0 1 2 3 4 5 6 7 8 9 10
Enzyme activity (U/ml)
Init
ial r
ate
(mM
per
min
)
0
30
60
90
120
150
180
210
240
Init
ial r
ate
(mM
per
hr)
ii
Edt
Pd
[Benzaldehyde] effect[Benzaldehyde] effect
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
0 20 40 60 80 100 120 140 160
[Benzaldehyde] (mM)
Init
ial r
ate
(mM
per
min
)
0
12
24
36
48
60
72
84
96
108
Init
ial r
ate
(mM
per
hr)
R2 = 0.9963
hib
hib
i BK
BK
dt
Pd
1
Monod-Wyman-Changeux (MWC) Model
Kb = 1 x 10-4 mM-1.34 h = 2.34
[Pyruvate] effect[Pyruvate] effect
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
0 30 60 90 120 150 180 210 240 270
[Pyruvate] (mM)
Init
ial
rate
(m
M p
er m
in)
0
12
24
36
48
60
72
84
96
108
Init
ial
rate
(m
M p
er h
r)
Michaelis – Menten kinetics Model
R2 = 0.9973
im
i
i AK
A
dt
Pd
Km = 10.6 mM
Enzyme deactivation effectEnzyme deactivation effect
0
20
40
60
80
100
120
0 20 40 60 80 100 120 140
Time (hr)
Rel
ativ
e en
zym
e ac
tivi
ty (%
)
0 mM
60 mM Bz
0
20
40
60
80
100
120
0 20 40 60 80 100 120 140
Time (h)
Rel
ativ
e en
zym
e ac
tivi
ty (
%)
Enzyme deactivation by benzaldehydeEnzyme deactivation by benzaldehyde
R2 = 0.9827
0 mM
200 mM
Enzyme deactivation effectEnzyme deactivation effect
mMBttEBkK
mMBttEK
tt
dt
Ed
ilagiidd
ilagid
lag
i 20010,;.
100,;
;0
21
1
Kd1 = 2.64 x 10-3 h-1
kd2 = 1.98 x 10-4 mM -1 h-1
tlag = 5.23 h
Overall rate constant & Overall rate constant & by-product rate constants determinationby-product rate constants determination
150 mM Bz150 mM Bz50 mM Bz50 mM Bz
Independent
prediction and
confirmation
k2, Vq, Vr
100 mM Bz100 mM Bz
Batch biotransformationBatch biotransformation
R2 = 0.9857
50 mM Bz ; 60 mM Pyr
0
16
32
48
64
80
0 1 2 3 4 5 6 7 8 9 10Time (h)
Co
nce
ntr
atio
n (
mM
)
0.0
0.8
1.6
2.4
3.2
4.0
En
zym
e ac
tivi
ty (
U/m
l)
[Pyruvate] [Benzaldehyde][Acetaldehyde] [Acetoin][R-PAC] Enzyme Activity
Batch biotransformationBatch biotransformation
R2 = 0.9981
150 mM Bz ; 180 mM Pyr
0
40
80
120
160
200
0 1 2 3 4 5 6 7 8 9Time (h)
Co
nc
en
tra
tio
n
(mM
)
0.0
0.8
1.6
2.4
3.2
4.0
En
zym
e
ac
tiv
ity
(U
/ml)
[Pyruvate] [Benzaldehyde]
[Acetaldehyde] [Acetoin][R-PAC] Enzyme Activity
Overall & by-products rate constantsOverall & by-products rate constants
Overall rate constant (k2 ) = 24.8 mol h-1 U-1
Acetaldehyde rate constant (Vq ) = 0.0156 h-1 (U/ml) -1
Acetoin rate constant (Vr ) = 0.00251 h-1 (U/ml) -1 mM-1
Theoretical & experimental modelTheoretical & experimental model
iim
ih
ib
hib
i
EAK
A
BK
BKk
dt
Pd
1
2
mMBttEBkK
mMBttEK
tt
dt
Ed
ilagiidd
ilagid
lag
i 20010,;.
100,;
;0
21
1
ii dt
Pd
dt
Bd
iiii dt
Rd
dt
Qd
dt
Pd
dt
Ad2
iiiriiqi
EAQVEAVdt
Qd
iiiri
EAQVdt
Rd
Simulation of biotransformationSimulation of biotransformation 100 mM Bz ; 120 mM Pyr
0
24
48
72
96
120
0 1 2 3 4 5 6 7 8 9Time (hr)
Co
nce
ntr
atio
n (
mM
)
0.0
0.7
1.4
2.1
2.8
3.5
En
zym
e ac
tivi
ty (
U/m
l)
.
[Pyruvate] [Benzaldehyde][Acetaldehyde] [Acetoin][R-PAC] Enzyme Activity
Confirmation of simulationConfirmation of simulation
R2 = 0.9953
100 mM Bz ; 120 mM Pyr
0
24
48
72
96
120
0 1 2 3 4 5 6 7 8 9Time (hr)
Co
nc
en
tra
tio
n (
mM
)
0.0
0.7
1.4
2.1
2.8
3.5
En
zym
e a
cti
vity
(U
/ml)
.
[Pyruvate] [Benzaldehyde][Acetaldehyde] [Acetoin][R-PAC] Enzyme Activity
Suggestion of substrates level to be maintained for optimum R-PAC production
Pulse feeding can be designed to achieve optimum R-PAC production
Prediction of fed-batch biotransformation profile
Model application in fed-batch systemModel application in fed-batch system
Simulation for prediction of optimum Simulation for prediction of optimum substrate levelsubstrate level
Hourly feed
1.2 Pyr/Bz
4.0 U/ml PDC
Initial Volume 1.00 L
0
50
100
150
200
250
300
350
0 15 30 45 60 75 90 105 120 135 150
Maintained Bz (mM)
R-P
AC
fo
rme
d, g
;
R-P
AC
pro
du
cti
vit
y, g
/da
y
.
0
20
40
60
80
100
120
140
Tim
e w
he
n r
em
na
nt
PD
C
.
is a
t 0
.5 U
/ml,
hr
.
R-PAC formed, gR-PAC productivity, g / dayTime when remnant PDC is at 0.5 U/ml, hr
0.0
10.0
20.0
30.0
40.0
50.0
60.0
0 4 8 12 16 20 24 28 32 36 40 44 48 52
Time (hr)
Vo
lum
e P
yr a
dd
ed (
ml)
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
Vo
lum
e B
Z a
dd
ed
(m
l)Feeding profile for 90 mM Bz, 108 mM PyrFeeding profile for 90 mM Bz, 108 mM Pyr
Hourly feed
10.3 M Bz
Hourly feed
1.4 M Pyr
Initial Volume 1.00 L
0
100
200
300
400
500
600
700
0 6 12 18 24 30 36 42 48 54
Time (hr)
Co
nc
en
tra
tio
n (
mM
)
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
En
zym
e a
cti
vit
y (
U/m
l)
R-PAC PyruvateAcetaldehyde AcetoinBenzaldehyde Enzyme activity
Predictive fed-batch profilePredictive fed-batch profile
Initial Volume 1.00 L
Final Volume 3.39 L
89 mg/U
ConclusionsConclusions Model provides good prediction for batch
biotransformation system
Model suggests substrate levels in the range of 90 mM Bz & 108 mM Pyr to be maintained in fed-batch system
Potential for 8-fold higher R-PAC per U than in batch system but verification by experiment is necessary
Note : Possible additional effects of inhibition (high R-PAC, acetaldehyde conc.) and inactivation (benzaldehyde droplets) may need to be considered
Professor Peter L. Rogers, Dr. Bettina Rosche
Dr. Russell Cail & Malcolm Noble
Wolfgang Nittel, Sue Jackson
Dr. Vanessa Sandford
Martin Zarka & Tony Gellert
Dr. Christopher Marquis
Mallika Boonmee, Alan Rushby
Royal Thai Government, BASF-AG
Lia, Allen, Cindy, Onn, Ronachai, Apple
AcknowledgementsAcknowledgements
QuestionsQuestions