Last Update: June 30, 2020

General

1. Description

1.1 Flowsheet

M e d i a
H u m a n I n s u lin P r o d u c tio n F lo w s h e e t F e rm e n t a t io n S e c t io n S - 1 0 8
E D T A S o l u t i o n

P r i m a r y R e c o v e r Ty r Si t oe cn -t Xi o - n1 0 0

S - 1 0 7 P - 6 / A F - 1 0 2
9 .3 0 M T /b a tc h
W a t e r
S - 1 0 6
A i r F i l t r a t i o n
2 .8 5 M T /b a tc h
L iq W a s t e 2

P - 2 / S T - 1 0 1
L iq w a s t e 1

H e a t S t e r i l i z a t i o n

A m m o n ia S - 1 4 2

P - 1 / B T - 1 0 1 S - 1 0 4
P - 1 1 / H G - 1 0 1
S - 1 0 1
S - 1 1 8
M i x i n g P - 5 / A F - 1 0 1
H o m o g e n i z a t i o n
P - 1 2 / D S - 1 0 1
A ir
P - 1 0 / B T - 1 0 2
A i r F i l t r a t i o n
P - 9 / D S - 1 0 1 P - 1 3 / B T - 1 0 3
S - 1 1 0 C e n t r i f u g a t i o n
B l e n d i n g / S t o r a g e
C N B r C/ He nC t O r i Of u Hg a t i o n
P - 8 / V T - 1 0 1 B l e n d i n g / S t o r a g e
3 7 . 4 1 m 3 / b a t c h
P - 7 / F R - 1 0 1 S - 1 4 3

P - 4 / G - 1 0 1 S t o r a g e
S - 1 0 9 M r E T O H / U r e 4a 3
F e r m e n t a t i o n 4 5 . 6 5 k g / b a t c h
C e n t r i f u g a l C o m p r e s s i o n 1 1 .0 4 M T /b a tc h W F I - 1

S - 1 2 7 L iq W a s t e 3

S - 1 2 2 W F I - 2

9 .5 5 M T /b a tc h
S - 1 2 1 S - 1 0 3

L iq W a s t e 4
G u a n H C l
S - 1 1 4
S - 1 1 5 S - 1 1 1
P - 1 9 / C S P - 1 0 1 P - 1 4 / D S - 1 0 1
P - 1 6 / D F - 1 0 1
L iq W a s t e 6 P - 1 7 / D E - 1 0 1
L iq W a s t e 5
R o t a r y E v a p o r a t o r C e n t r i f u g a t i o n
D i a f i l t r a t i o n
1 2 5 5 2 . 7 1 k g / b a t c h D e a d - E n d F i l t r a t i o n
S - 1 5 8

P - 2 1 / D F - 1 0 1 P - 1 5 / V - 1 0 1
S - 1 4 6 S - 1 5 9
P - 1 8 / V - 1 0 2
D i a f i l t r a t i o n I B S o l u b i l i z a t i o n
S - 1 4 7 S - 1 6 0
P - 2 0 / V - 1 0 3
C N B r C l e a v a g e
E n z y m e s - N e w

S u l f i t o l y s i s
R e a c t io n s S e c tio n W F I - 4
S - 1 3 4

S - 1 3 5 S - 1 4 8
W F I - 3
S - 1 3 1

S - 1 3 6 S - 1 4 9

S - 1 2 3
S - 1 5 4
S - 1 2 5 S - 1 0 2
L iq W a s t e 1 1
S - 1 2 9 L iq W a s t e 1 0
8 3 6 9 . 7 1 k g / b a t c h S - 1 3 3
1 8 . 1 6 M T / b a t c h
S - 1 5 2

S - 1 1 9 S - 1 3 0
L iq W a s t e 7
P - 2 7 / D F - 1 0 2
S - 1 4 4 M r E t O H
8 9 . 1 5 M T / b a t c h L iq W a s t e 9
L iq W a s t e 8 S - 1 3 8
P - 2 4 / D F - 1 0 2 D i a f i l t r a t i o n
P - 2 8 / C - 1 0 3
S - 1 3 2 5 5 . 3 9 M T / b a t c h S - 1 6 5
D i a f i l t r a t i o n
P - 2
S
5
- 1 7 3
/ C - 1 0 2 P - 2 6 /
F V i n- 1 a 0 l 5 P u r i f i c a t i o n S e c t i oSn - S e p h a r o s e
S - 1 6 1

4 5 3 9 . 6 3 k g / b a t c h
P - 2 2 / C - 1 0 1 P - 2 3 / V - 1 0 4 1 7 8 7 . 6 5 k g / b a t c h
H I C C o l uE m n nz y m e C o n v e r s i o n
W F I - 6
S - 1 8S 6 - S e p h a r o s e R e f o l d i n g S - 1 2 6 S - 1 6 6
S - 1 7 4
S - 1 6 2
S - 1 7 5 S - 1 6 7
S - 1 3 7 W F I - 5

1 1 .5 0 kg /b a tc h S - 1 2 4

P r o d u c t
S - 1 7 2
L iq W a s t e 1 7
L iq W a s t e 1 4
P - 3 6 / F D R - 1 0 1 L iq W a s t e 1 2

1 . 6 1 M T / b a t c h
S - 1 5 7
F r e e z e D r y i n g L iq W a s t e 1 6 P - 3 3 / D F - 1 0 5
2 . 6 2 M T / b a t c h
P - 3 1 / D F - 1 0 4
L iq W a s t e 1 3 P - 2 9 / D F - 1 0 3
D iL a i qf i lWt r aa st it oe n1 5
1 . 9 4 M T / b a t c h
D i a f i l t r a t i o n
1 3 . 1 6 M T / b a t c h D i a f i l t r a t i o n
4 0 . 4 0 M T / b a t c Ph - 3 2 / C - 1 0 5 P - 3 0 / C - 1 0 4
P - 3 5 / B C F - 1 0 1 P - 3 4 / V - 1 0 6

G e l F i l t r a t i o n R P - H P L C
B a s k e t C e n t r i f u g Ca rt yi o s nt a l l i z a t i o n

1.2 Filename (.spd) C:\Users\gires\Documents\escuela\semestre 8\procesos\Insulina.spf

2. Size

2.1 Batch Throughput 11.27 kg MP/batch

2.2 Annual Throughput 1803.93 kg MP/yr
MP = Total Flow of Stream 'Product'

3. Economics
3.1 Total Investment 185777944 $
3.2 Total Revenues 180352629 $/yr
3.3 Operating Cost 111682508 $/yr
3.4 Unit Production Ref. Rate 1803.93 kg MP/yr
3.5 Unit Production Cost
incl. depreciation 61910.77 $/kg MP
excl. depreciation 53944.24 $/kg MP
MP = Total Flow of Stream 'Product'

4. Project Indices

4.1 Gross Margin 38.08 %

4.2 Return On Investment 29.91 %
4.3 Payback Time 3.34 years
4.4 IRR Before Taxes 45.70 %
4.5 IRR After Taxes 33.36 %
4.6 NPV at (7.00 %) 243121784 $
et
 Last Update: June 30, 2020
Materials

1. Tables

1.1 Material Consumption

Material kg/yr kg/batch kg/kg MP
Acetic-Acid 975741.15 6098.38 540.90
Acetonitrile 764739.16 4779.62 423.93
Air 3930093.35 24563.08 2178.63
Ammonia 81552.60 509.70 45.21
Ammonium Acetat 181.23 1.13 0.10
CNBr 15268.47 95.43 8.46
EDTA 10418.05 65.11 5.78
Enzymes 3.38 0.02 0.00
Formic acid 1751525.41 10947.03 970.95
Glucose 782238.24 4888.99 433.63
Guanidine HCl 805592.97 5034.96 446.58
H3PO4 (5% w/w) 3994227.02 24963.92 2214.18
MrEtOH 98659.92 616.62 54.69
Na2O6S4 24158.97 150.99 13.39
NaOH (0.5 M) 3857223.59 24107.65 2138.24
NH4HCO3 5550.52 34.69 3.08
Salts 71428.41 446.43 39.60
Sodium Chloride 775548.98 4847.18 429.92
Sodium Hydroxid 137238.78 857.74 76.08
Sodium sulfite 48317.94 301.99 26.78
TRIS Base 43162.33 269.76 23.93
Triton-X-100 3035.23 18.97 1.68
Urea 3054069.52 19087.93 1693.01
Water 9727942.79 60799.64 5392.65
WFI 51914344.51 324464.65 28778.52
Zinc Chloride 320.00 2.00 0.18
TOTAL 82872582.55 517953.64 45940.10

1.2 Material Cost

Unit Cost Annual Annual Cost Cost
Bulk Material %
($) Amount ($) ($/kg MP)
Acetic-Acid 2.50 975741.00 kg 2439353.00 1352.25 8.08
Acetonitrile 3.00 764739.00 kg 2294217.00 1271.79 7.60
Air 0.00 3930093.00 kg 0.00 0.00 0.00
Ammonia 0.70 81553.00 kg 57087.00 31.65 0.19
Ammonium Acetat 15.00 181.00 kg 2718.00 1.51 0.01
CNBr 11.00 15268.00 kg 167953.00 93.10 0.56
EDTA 18.50 10418.00 kg 192734.00 106.84 0.64
Enzymes 500000.00 3.00 kg 1691128.00 937.47 5.60
Formic acid 1.60 1751525.00 kg 2802441.00 1553.52 9.28
Glucose 0.60 782238.00 kg 469343.00 260.18 1.55
Guanidine HCl 2.15 805593.00 kg 1732025.00 960.14 5.74
H3PO4 (5% w/w) 1.00 3994227.00 kg 3994227.00 2214.18 13.23
MrEtOH 3.00 98660.00 kg 295980.00 164.08 0.98
Na2O6S4 0.60 24159.00 kg 14495.00 8.04 0.05
NaOH (0.5 M) 0.50 3857224.00 kg 1928612.00 1069.12 6.39
NH4HCO3 1.00 5551.00 kg 5551.00 3.08 0.02
Salts 1.00 71428.00 kg 71428.00 39.60 0.24
Sodium Chloride 1.23 775549.00 kg 953925.00 528.80 3.16
Sodium Hydroxid 3.50 137239.00 kg 480336.00 266.27 1.59
Sodium sulfite 0.40 48318.00 kg 19327.00 10.71 0.06
TRIS Base 6.00 43162.00 kg 258974.00 143.56 0.86
Triton-X-100 1.50 3035.00 kg 4553.00 2.52 0.02
Urea 1.52 3054070.00 kg 4642186.00 2573.38 15.37
Water 0.05 9727943.00 kg 486397.00 269.63 1.61
WFI 0.10 51914345.00 kg 5191434.00 2877.85 17.19
Zinc Chloride 12.00 320.00 kg 3840.00 2.13 0.01
TOTAL - - - 30200264.00 16741.40 100.00

1.3 Overall Balance

(kg/Batch)
COMPONENT INITIAL INPUT OUTPUT FINAL OUT
Acetic-Acid 0.00 6098.38 6098.38 2.87 2
Acetonitrile 0.00 4779.62 4779.62 7.01 7
Ammonia 0.00 509.70 273.87 0.15 - 235.
Ammonium Acetat 0.00 1.13 1.13 0.00 0
Biomass 0.00 0.00 22.87 0.00 22
Carb. Dioxide 0.00 0.00 2321.80 1.31 2323
Cell Debris 0.00 0.00 549.70 0.00 549
CNBr 0.00 95.43 95.43 0.00 0
Cont Proteins 0.00 0.00 488.75 87.79 576
Denatured Proin 0.00 0.00 3.28 3.51 6
EDTA 0.00 65.11 65.11 0.00 0
Enzymes 0.00 0.02 0.02 0.02 0
Formic acid 0.00 10947.03 10947.03 24.43 24
Glucose 0.00 4888.99 1522.17 0.01 - 3,366.
Guanidine HCl 0.00 5034.96 5034.96 1123.45 1123
IBs 0.00 0.00 19.27 0.00 19
Insulin 0.00 0.00 5.17 60.37 65
Insulin Crystal 0.00 0.00 11.50 0.00 11
MrEtOH 0.00 616.63 616.63 0.47 0
Na2O6S4 0.00 150.99 149.60 33.38 31
NH4HCO3 0.00 34.69 34.69 7.74 7
Nitrogen 218.23 19000.40 18996.26 222.37 0
Oxygen 66.25 5768.15 4488.23 66.79 - 1,279.
Phosphoric Acid 0.00 1248.20 1248.20 0.00 0
Proinsulin 0.00 0.00 4.91 1.57 6
Proinsulin-SSO3 0.00 0.00 10.94 47.59 58
Salts 0.00 446.43 221.97 0.00 - 224.
Sodium Chloride 0.00 4847.18 4847.18 16.24 16
Sodium Hydroxid 0.00 1330.25 1330.25 0.00 0
Sodium sulfite 0.00 301.99 300.59 67.07 65
TRIS Base 0.00 269.77 269.77 0.01 0
Triton-X-100 0.00 18.97 18.97 0.01 0
Trp-Proinsulin 0.00 0.00 8.69 7.84 16
Urea 0.00 19087.93 19087.93 3.63 3
Water 0.00 60799.64 62460.61 0.20 1661
WFI 0.00 371815.51 371815.51 9158.06 9158
Zinc Chloride 0.00 2.00 2.00 0.00 0
TOTAL 284.48 518159.11 518152.97 10943.88 10653
 OUT-IN
2.87
7.01
- 235.677
0.00
22.87
2323.10
549.70
0.00
576.54
6.79
0.00
0.02
24.43
- 3,366.810
1123.45
19.27
65.55
11.50
0.47
31.98
7.74
0.00
- 1,279.390
0.00
6.47
58.53
- 224.453
16.24
0.00
65.67
0.01
0.01
16.53
3.63
1661.16
9158.06
0.00
10653.27
 Last Update: June 30, 2020
Utilities & Labor

1. Tables

1.1 Heat Transfer Agent Demand

1.1a Total Heat Transfer Agent Demand
Heat Transfer Agent kg/yr kg/batch kg/kg MP
NaCl Brine 22066110.22 137913.19 12232.26
Steam 730674.95 4566.72 405.05
Glycol 72491541.24 453072.13 40185.41
Cooling Water 48456684.80 302854.28 26861.78
Chilled Water 210817830.54 1317611.44 116866.05

1.1b Heat Transfer Agent Demand (Section Breakdown)

NaCl Brine kg/yr kg/batch kg/kg MP
Fermentation 22000994.65 137506.22 12196.17
Final Purification 65115.57 406.97 36.10
TOTAL 22066110.22 137913.19 12232.26

Steam kg/yr kg/batch kg/kg MP

Fermentation 322467.72 2015.42 178.76
Primary Recovery 20800.00 130.00 11.53
Reactions 385772.19 2411.08 213.85
Final Purification 1635.03 10.22 0.91
TOTAL 730674.95 4566.72 405.05

Glycol kg/yr kg/batch kg/kg MP

Primary Recovery 54254475.85 339090.47 30075.76
Reactions 17417662.93 108860.39 9655.41
Final Purification 819402.46 5121.27 454.23
TOTAL 72491541.24 453072.13 40185.41

Cooling Water kg/yr kg/batch kg/kg MP

Fermentation 48456684.80 302854.28 26861.78
TOTAL 48456684.80 302854.28 26861.78

Chilled Water kg/yr kg/batch kg/kg MP

Fermentation 205103145.52 1281894.66 113698.14
Reactions 5546805.44 34667.53 3074.85
Final Purification 167879.57 1049.25 93.06
TOTAL 210817830.54 1317611.44 116866.05

1.1c Heat Transfer Agent Demand (Procedure Breakdown)

NaCl Brine kg/yr kg/batch kg/kg MP
Fermentation
P-7 22000994.65 137506.22 12196.17
Section Total 22000994.65 137506.22 12196.17
Final Purification
P-34 65115.57 406.97 36.10
Section Total 65115.57 406.97 36.10
TOTAL 22066110.22 137913.19 12232.26

Steam kg/yr kg/batch kg/kg MP

Fermentation
P-2 316067.72 1975.42 175.21
P-7 6400.00 40.00 3.55
Section Total 322467.72 2015.42 178.76
Primary Recovery
P-14 8000.00 50.00 4.43
P-8 12800.00 80.00 7.10
Section Total 20800.00 130.00 11.53
Reactions
P-15 33403.42 208.77 18.52
P-18 47634.55 297.72 26.41
P-19 96000.00 600.00 53.22
P-20 16000.00 100.00 8.87
P-24 170269.45 1064.18 94.39
P-26 22464.77 140.40 12.45
Section Total 385772.19 2411.08 213.85
Final Purification
P-36 1635.03 10.22 0.91
Section Total 1635.03 10.22 0.91
TOTAL 730674.95 4566.72 405.05

Glycol kg/yr kg/batch kg/kg MP

Primary Recovery
P-9 6190100.83 38688.13 3431.46
P-11 34461696.29 215385.60 19103.71
P-12 6184927.94 38655.80 3428.59
P-14 7417750.80 46360.94 4112.00
Section Total 54254475.85 339090.47 30075.76
Reactions
P-23 17417662.93 108860.39 9655.41
Section Total 17417662.93 108860.39 9655.41
Final Purification
P-27 819402.46 5121.27 454.23
Section Total 819402.46 5121.27 454.23
TOTAL 72491541.24 453072.13 40185.41

Cooling Water kg/yr kg/batch kg/kg MP

Fermentation
P-2 22464255.58 140401.60 12452.97
P-4 25992429.22 162452.68 14408.80
Section Total 48456684.80 302854.28 26861.78
TOTAL 48456684.80 302854.28 26861.78

Chilled Water kg/yr kg/batch kg/kg MP

Fermentation
P-7 205103145.52 1281894.66 113698.14
Section Total 205103145.52 1281894.66 113698.14
Reactions
P-16 3728168.92 23301.06 2066.70
P-18 1003063.80 6269.15 556.04
P-20 471617.63 2947.61 261.44
P-21 343955.10 2149.72 190.67
Section Total 5546805.44 34667.53 3074.85
Final Purification
P-29 68968.30 431.05 38.23
P-31 46030.54 287.69 25.52
P-33 52880.73 330.50 29.31
Section Total 167879.57 1049.25 93.06
TOTAL 210817830.54 1317611.44 116866.05

1.2 Power Demand

1.2a Total Power Demand
Power Type kW-h/yr kW-h/batch kW-h/kg MP
Std Power 1500536.79 9378.35 831.82
TOTAL 1500536.79 9378.35 831.82

1.2b Power Demand (Section Breakdown)

Std Power kW-h/yr kW-h/batch kW-h/kg MP
Fermentation 769882.34 4811.76 426.78
Primary Recovery 540892.76 3380.58 299.84
Reactions 162136.86 1013.36 89.88
Final Purification 27624.85 172.66 15.31
TOTAL 1500536.79 9378.35 831.82
1.2c Power Demand (Procedure Breakdown)
Std Power kW-h/yr kW-h/batch kW-h/kg MP
Fermentation
P-1 592.95 3.71 0.33
P-4 295121.64 1844.51 163.60
P-7 320191.28 2001.20 177.50
Unlisted Equipment 38494.12 240.59 21.34
General Load 115482.35 721.76 64.02
Section Total 769882.34 4811.76 426.78
Primary Recovery
P-9 79120.00 494.50 43.86
P-11 195354.19 1220.96 108.29
P-12 79120.00 494.50 43.86
P-14 79120.00 494.50 43.86
Unlisted Equipment 27044.64 169.03 14.99
General Load 81133.91 507.09 44.98
Section Total 540892.76 3380.58 299.84
Reactions
P-16 29898.88 186.87 16.57
P-21 20076.03 125.48 11.13
P-24 79734.57 498.34 44.20
Unlisted Equipment 8106.84 50.67 4.49
General Load 24320.53 152.00 13.48
Section Total 162136.86 1013.36 89.88
Final Purification
P-27 12152.07 75.95 6.74
P-29 4025.55 25.16 2.23
P-31 2686.72 16.79 1.49
P-36 147.28 0.92 0.08
P-34 1.71 0.01 0.00
P-33 3086.55 19.29 1.71
Unlisted Equipment 1381.24 8.63 0.77
General Load 4143.73 25.90 2.30
Section Total 27624.85 172.66 15.31
TOTAL 1500536.79 9378.35 831.82

2. Charts
 Last Update: June 30, 2020
Equipment

1. Charts

1.1 Equipment Occupancy

C IP -S k id -1 0 1
C IP -S k id -1 0 2
C IP -S k id -1 0 3
C IP -S k id -1 0 4
C IP -S k id -1 0 5
C IP -S k id -1 0 6
B T -1 0 1
S T -1 0 1
F R -1 0 1
G -1 0 1
M X -1 0 1
A F -1 0 1
Main Equipment & CIP Skids

A F -1 0 2
V T -1 0 1
D S -1 0 1
B T -1 0 2
H G -1 0 1
B T -1 0 3
V -1 0 1
D F -1 0 1
D E -1 0 1
V -1 0 2
C S P -1 0 1
V -1 0 3
C -1 0 1
V -1 0 4
D F -1 0 2
C -1 0 2
V -1 0 5
C -1 0 3
D F -1 0 3
C -1 0 4
D F -1 0 4
C -1 0 5
D F -1 0 5
V -1 0 6
B C F -1 0 1
F D R -1 0 1
da y 1 2 3 4 5 6 7 8
wk 1
9 10 11 12 13
2