Novasep Process - Frontiers in Biorefining · Novasep Process: Advanced Purification Technologies...

Novasep Process: Advanced Purification Technologies for Bio Based Chemicals 1

Novasep Process: Advanced Purification Technologies for Bio-Based Chemicals

Frontiers Bio-Refining 2012


The challenge!

Producing Bio-Based Chemicals


C5 Sugars

Lignin

C6 Sugars

Pre-Treatment

Extraction Separation

How to Get Pure Fractions


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


• 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


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


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

http://upload.wikimedia.org/wikipedia/en/6/6d/Quadruple_Hydrogen_Bond_AngewChemIntEd_1998_v37_p75.jpg


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


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


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


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…


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


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


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


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


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


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

//upload.wikimedia.org/wikipedia/commons/e/e1/L-lysine-2D-skeletal.png

//upload.wikimedia.org/wikipedia/commons/3/33/Nylon_6%2C6.png

//upload.wikimedia.org/wikipedia/commons/c/c2/Cadaverine-2D-skeletal.png


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

//upload.wikimedia.org/wikipedia/commons/2/2d/D-Glucons%C3%A4ure_Keilstrich.svg

//upload.wikimedia.org/wikipedia/commons/7/72/Glucaric_acid_structure.svg


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


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)

//upload.wikimedia.org/wikipedia/commons/9/9f/Bernsteins%C3%A4ure2.svg

http://en.wikipedia.org/wiki/Molar_mass

http://en.wikipedia.org/wiki/Boiling_point

http://en.wikipedia.org/wiki/Solubility

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


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


Here’s to your success!

John Bhatt

[email protected]

Novasep Process - Frontiers in Biorefining · Novasep Process: Advanced Purification Technologies...

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