enabling generation iii by interfacing measurement...
TRANSCRIPT
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Enabling Generation III by Interfacing Measurement Science to the Generation 1 Platform
Brian Marquardt Ph.D. Charles Branham, Wes Thompson, Thomas Dearing, Michael Roberto, Lauren Hughs CPAC Applied Physics Laboratory University of Washington
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Perfect Process Analyzer? Pressure, Temperature and Flow
Process IR
O2 Sensor
Process Raman
Mass Flow Control
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Where Does NeSSI Fit in the Lab Instrument/Sensor Interfaces
Design standards make development simpler Reduced toolset to be mastered Reduced sample variability to account for
Calibration/validation built-in Consistent physical environment for measurement Stream switching and/or mixing allow generation of
standards to match analytical requirements
Reaction monitoring Microreactors and continuous flow reactors Batch reactors (with fast loop)
Sample Preparation Gas handling (mixing, generation, delivery) Liquid handling (mixing, dilution, conditioning, etc.)
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NeSSI with an Array of Micro-Analytical Techniques will Impact Many Industries
• Process Control • Process Optimization • Product Development
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Thermo/C2V Fast Micro-GC
http://www.c2v.nl/ as well as http://www.thermo.com
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NeSSI™ Compatible GC/LC Diaphragm Valve
Inject valves
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Applied Analytics Inc. Diode Array OMA-300 A Fiber-optics-diode-
array process analyzer For on-line concentration
monitoring
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NeSSI Ballprobe - Raman/NIR/UV
Matrix Solutions: www.ballprobe.com
Ballprobe Specs. •Hastalloy c-276
Ti, SS, Monel •Sapphire optic •Std. temp range:
-40 – 350° C •Pressure:
0-350 Barr
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Kaiser Airhead Raman Gas Probe
AirHeadTM Probe with compression mount
NeSSI interface
AirHeadTM Probe with
NPT- Threaded mount
NeSSI interface
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NeSSI™ IR Gas Cell
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micrOptix
NeSSI UV-Vis/NIR Sensor
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Cactus, Inline Fluid Healthcare Monitor
Cactus is used to monitor the health of motor oils and hydraulic fluids. This transmitter combines physical/chemical, thermal & electrical measurements with high level computation algorithms to provide users with a single unit, named HEAL.
Output range & unit 0 to 100 HEAL
Measurement time 1 sec
Fluid operating range
Density 600 Kg.m-3 to 1100 Kg.m-3
Pressure Atm to 100 bar
Temperature -25 °C to 110 °C
Viscosity 0.3 cP to 200 cP
Water saturation Up to 100%
Performances Repeatability* 1 %
Accuracy* 3 %
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H2Scan Adaptation to NeSSITM Platform • Hydrogen specific: 0.5% H2 to 100% H2 v/v
• Response time (T90) < 30 sec
• In-line, real-time measurements in process gas streams up to 100OC
• Unique models for CO, H2S, wet CL2
• 4-20mA, RS422 or RS232 serial connectivity
• Stable results
• On-site verification and calibration
• Approved for hazardous locations – Intrinsically safe design – ATEX certificate granted; UL pending
• Cost effective to buy / install / maintain
• Field verification and calibration kit available
http://www.h2scan.com/
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Astute Sampling System
GAS TREATMENT
COLUMN
Sampling + Sensors & micro-analyzers
Astute System with C2V Micro GC and H2Scan hydrogen analyzer Process
www.eif-filters.com
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Agilent NeSSI Dielectric Sensor Cable to Agilent
Network Analyzer
Swagelok 2-Port
Valve Base
Dielectric Probe
Inner Body
O-ring (inside)
Outer Body
Close up of Coaxial
Probe Tip
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Teledyne: NeSSI Oxygen Sensor Fuel Cell or Zirconium Oxide Sensors Offer an SP76 compliant oxygen
sensor Available concentration ranges
0-10 ppm, 0-1000 ppm, 0-3%, 0-25%, 0-100% oxygen
Response time T90% < 45 seconds, Fuel Cell T90% < 10 seconds, Zirconium Oxide
Operating Temperature: 0-50˚C Signal output
4-20 mA and 0-10 VDC
http://www.teledyne-ai.com/
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Mechatest Sampling Solutions
NeSSI Liquid Sampler Compliant with ANSI/ISA 76.00.02 38.2 mm
(1.5 in.) footprint. Three Port configuration: Sample Inlet,
Bypass and Vent. Quick and safe operation, low dead volume
design with bypass. Manual or Automatic sampling In-line Sampling Closed Loop and Emission Free Sampling Easy in operation
http://www.mechatest.nl/
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NeSSI based research and developments at APL
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Initial NeSSI Gas Blending System
NeSSI Gas/Vapor System
Aspectrics EPIR w/ glass cell
N2 Waste
NeSSI Flow Cell
ASI microFAST GC
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Analog NeSSI Gas Mixture System
Features of Circor System obtained for UM: 1. 4 gasses line, able to produce and maintain gas mixtures 2. Fully automated system, set and forget capability
Automated NeSSI System
4 x Gasses
Mixed Gases
Mass Flow Controllers
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Calibrated Analog Gas Mixer
- 3 stream calibrated mixing with fiber optic oxygen/temperature/humidity sensing
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Digital Calib. Gas Generation System Features of NeSSI System : • Fully digital
• RS 485 • 4 Stage dilution,
able to produce and maintain gas concentrations in 1-5 ppm range
• Fully automated system, set and forget capability
• Integrated C2V NeSSI compat. GC
• Calib, platform for gas sensor dev.
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Digital Gas Calibration System
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Digital Serial Gas Diluter
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Gas Calib. System LabView Control Program • Perform automated DoE calibration runs • Input and log sensor, reference, temperature and pressure feeds • System designed for full digital (plug and play) performance as h/w matures
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Modular NeSSI Oxygen Gas Sensor
Exploded View
1/16 in bifurcated fiber optic fiber
1/16 to 1/8 in Swagelok union
Agilent NeSSI Mount
Sensor Body
Close up of Outer Body Tip
Vapochromic Tip
Fiber optic ferrule with plastic housing
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Sensor response to O2 Gas
Pre
dict
ed O
2 %
Calculated O2 %
R2 = 0.990, 3 PC RMSEC = 1.0744
20 replicates at each concentration Concentration range: 0 -100% Oxygen 16 ms reversible response full range
Inte
nsity
(cou
nts)
Wavelength (nm)
100 %
0%
120
100
80
60
40
20
0 100 90 80 70 60 50 40 30 20 10 0
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0 10 20 30 40 50 600
10
20
30
40
50
60
Measured Oxygen Concentration(micromol/liter)
Pred
icte
d O
xyge
n C
once
ntra
tion(
mic
rom
ol/li
ter)
R2 = 0.9982 Latent VariablesRMSEC = 0.90163Bias = -7.1054e-015
Sensor Response for O2 in Solution
5 replicates at each concentration Concentration range: 1 μmol/L - 55 μmol/L 3.2 sec reversible response – full range
1 μmol/L = 32.5 ppb
500 550 600 650 700 7500
0.2
0.4
0.6
0.8
1
Wavelength(nm)
Rea
lativ
e In
tens
ity
55 μmol/L
1 μmol/L
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Vapochromic Oxygen Sensor
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Raman Filtration/Sampling Sys
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Initial NeSSI Permeation System
NeSSI Gas/Vapor System
Permeation Tower
Aspectrics EPIR w/ glass cell
N2 Waste
NeSSI Flow Cell
ASI microFAST GC
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Permeation Apparatus – ver. 2
- CPAC inspired and Parker built prototype permeation apparatus - Currently, used to generate calibrated organic vapor samples for sensor testing - Vapor calibration NeSSI system with Kaiser Airhead gas probe for analysis
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Advanced NeSSI Perm. System Ver. 3
MFC 1
MFC
2
MFC 3
Perm
eatio
n Ap
para
tus
Vapor
Balance Gas
Sample to IR
Heater Set Temp. 65˚C Permeation App. Temp. 48˚C
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Permeation System – Ver 4
Parker NeSSI Permeation Apparatus
Aspectric EP-IR
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4000 3800 3600 3400 3200 3000 2800 2600 2400 2200 2000-2
-1
0
1
2
3
4
5x 10-3
Wavenumber (cm-1)
Abs
orba
nce
(Arb
itrar
y U
nits
)
Temperature Permeation Results: IR Spectra
H2O
Ethanol CO2 As Temp Decreases the Signal Decreases 85˚C
65˚C
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NeSSI Continuous Flow NMR System
Pump
Sampling System
Reactor
NMR
• Challenges with steel – polymer NeSSI system being manufactured to perform this measurement
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PEEK NMR NeSSI Substrate
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Goal: to improve reaction monitoring and optimization through the use of continuous glass flow reactors, NeSSI and analytics
Funded by the FDA to demonstrate the benefits of improved reactor design, effective sampling and online analytics to increase process understanding (QbD)
Demonstrating Quality by Design
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CF Reactor and Raman Analyzer
4 channel, 785 nm Kaiser Optical Systems Rxn2 probes placed at different reactor zones
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Raman Analysis of CF Reactor
3 4
1
2
• Monitor reaction with 4 channel 785 nm Raman system • NeSSI sampling systems (1-4) equipped with Raman ballprobes • Online GC also used as post quench online analyzer (4)
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NeSSI™ Sampling System for Reactor
Raman Probe
monitor
bypass
clean
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NeSSI™ and Raman Probe Images
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Continuous Chemical Synthesis
- NeSSI flow management system (P, T, flow sensors, backpressure, filter) - NeSSI analytic sampling system (mulit probe Raman, IR, NIR, RI, Density, …)
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Analytical Control System Design
Feedback & Control
Process Modeling
Data Fusion
Analytics and Data Handling
Hardware Control and Monitoring (Software)
Hardware – NeSSI, Raman, Other PAT, Reactor
Optimization
44
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Interface with continuous flow reactor Mechanisms to ensure safe reactor
conditions Combined waste outlets from safety mechanisms
On-line analytics Temperature, flow, pressure
Product / Waste stream mechanism downstream of analytics
Open ports to allow for new analytics
Continuous Flow System Targets
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HPLC Pump (Flow Rate)
Back Pressure Regulator Flow Meter Pressure
Gauge
•Reactant 1
Thermocouple Raman Other PAT
Flow Meter Pressure Gauge Thermocouple
•Product
Raman Infrared Needle Valve
Temperature Control
Control Analytics
Target System
HPLC Pump (Flow Rate)
Back Pressure Regulator Flow Meter Pressure
Gauge
•Reactant 2
Thermocouple Raman Other PAT
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Preliminary Schematic
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Reagent Sample Lines
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Reactor Product Line
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Current Reactor Iterative design
process, with multiple redesigns New analytics brought
to bear on system New safety and valve
mechanisms NeSSI allows for this
iterative process to proceed rapidly at practical costs
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Esterification of benzoic acid
Straight-forward, pharmaceutically relevant
Strong dependence on temperature, flow rates
Chemical Reaction
Wiles, C., Watts, P. 2009
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Temperature vs. Reaction Progress
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PLS Raman Calibration Model
0 20 40 60 80 1000
10
20
30
40
50
60
70
80
90
100
Yield Measured by HPLC (%)
Yiel
d Pr
edic
ted
by R
aman
(%)
PLS Model - Raman Prediction vs. HPLCHigh Concentration Factorial Calibration
R^2 = 0.9992 Latent VariablesRMSEC = 0.91141Bias = 0
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NeSSI for Fermentation Monitoring
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Real-time Analysis of a Simulated Batch Fermentation Process
Simulated Fermentation liquor 900 mL of synthetic sugar water was
fermented with yeast for 8 hours The solution of sugar was held at 30˚C
and pH 6 for the duration of experiment. Glucose additions were added when
ethanol peak equilibrated. The final total sugar concentration in the reactor was 25 g/L glucose
NeSSI Fast-Loop Kaiser Optical Systems Raman
½” ballprobe with sapphire optic, 250mW power at probe tip
Average of six, 5 second exposures Mettler React-IR
MCT Detector Silver Halide Immersion Probe Diamond ATR
Fiber Optic O2 Sensor Cassini O2 Sensor
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NeSSI Ferm. Fast-loop Design
• Custom designed NeSSI interfaces for all process analyzers in my lab • Plug and play analytics for any flowing system (liquid, slurry or gas)
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Ethanol HPLC and Raman PC1
0 50 100 150 200 250 300 350 400 0
2
4
6
8
10
12
Time (Min)
Etha
nol (
mg/
mL)
-8
-6
-4
-2
0
2
4
6
8
Scor
es P
C1
HPLC Concentration Scores of Raman Data
After validating the loadings with the standard spectra, we can compare the scores plots (change in Raman spectra with time) with the reference method (change in concentration with time)
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Glucose HPLC and Raman PC2
0 50 100 200 250 300 350 400 0
1
2
3
4
5
6
Glu
cose
(mg/
mL)
150 -3
-2
-1
0
1
2
3
4
Time (Min)
Scor
es P
C2
HPLC Concentration Scores of Raman Data
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Sterilization of NeSSI Fast Loop? Concerns for sterilization
The flow path for a single NeSSI block has potential eddy points that can hold organisms
O-rings, seams and seals can allow holdup of biological material
Potential sterilization methods 10% bleach solution, initially
flowed through system, then held static to allow diffusion
Steam sterilization, heats entire block to 120°C
Autoclave
Substrate
Top Mount Component
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Bleach Sterilization Method Rinsed 10% Bleach Solution for 1 hour Sterile Water Rinse
Filled Sterile Growth Media
Incubated 37°C for 72 hours
Swabbed
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Culture plates
1. End piece (Start Flow) 2. Valve substrate 3. Top mount 3 4. Substrate 3 5. Top mount 4
6. Substrate 4 7. Top mount 5 8. Substrate 5 9. Valve substrate 10.End piece (End Flow)
1 2
3 5 7
9 4 6 8 10
contaminated
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Conclusions and Challenges Demonstrated sterilization of NeSSI
components Possibly contaminated by residual cells
trapped in valve seat Pre autoclaving worked to remove
majority of possible contamination points O-rings and tubing
Next step – Sterile pumps and tubing Food grade diaphragm pump Stainless steel tubing Diaphragm valves to replace ball valves
More Dev. in Steam sterilization 120°C for 15 minutes (15 psi)
More work to be done!
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Steam Sterilization Experiments
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Steam Sterilization Method Sterilized Sterile Water Rinse ~ 500mL 120 °C for 15 min
Filled Sterile growth media is pumped by head pressure of compressed gas
Incubated 37°C for 72 hours
Swabbed Substrates sampled onto bacterial streak plates
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Culture Plates
1. End piece (Start Flow) 2. Valve substrate 1 3. Substrate 3 4. Top mount 3 5. Substrate 4 6. Substrate 5 7. Valve substrate 6 8. End piece (End Flow)
1
2 3 5 7 4 6
8
contaminated
• Contamination only found in end connector components
• This has been a continuing challenge with all sterilization routines
• Difficult to keep end connectors sterile due to fill cycles for media to test long term sterility
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Steam Sterilization Autoclave procedure, 120 °C for 15 minutes Temperature and pressure measured at end of block to
ensure the entire system is controlled New Valves
Pin valves were replaced with Hastelloy diaphragm valves to reduce possibility of hold up in valve seat
Sterile pumping mechanism Peristaltic pump replaced with compressed air pump Air is passed through a 0.2 µm filter into the headspace of
a sealed 2 L jar containing sterile media, forcing the media through the NeSSI substrate
All tubing is stainless steel
Differences from bleach sterilization
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Demonstrated sterilization of NeSSI components Possibly contaminated by residual cells trapped in threads of end
caps Steam sterilization is a valid method of sterilization for NeSSI
components O-rings and tubing are compatible with autoclave conditions Ensures a sterile flow path without exposing external parts to hot and
humid conditions Next step – Top mount components
Sterilization of top mount components will be dependent on the materials and flow path of the components themselves
Next step – Full integration to NeSSI System Integrate rinse stream and boiler system to NeSSI fast loop sampling
system Create digital control system for automatic sterilization
Conclusions and Challenges
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LinkedIn NeSSI Group www.linkedin.com - search in groups tab for NeSSI and join!!!
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Questions?????
Thank You!!