progress report – week 9 section ac, group 2 presented by andrew amodei teammates: david bergsman,...
TRANSCRIPT
Progress Report – Week 9
Section AC, Group 2Presented by Andrew Amodei
Teammates: David Bergsman, Michael Huang, Elizabeth Lam
May 24th, 2012
Goals of the Week• Finish individual design projects– Water for injection system– Facility layout– Downstream columns– Equipment and labor scheduling
• Finish debugging spreadsheet• FEMA analysis• Update stream tables and PFD• Complete and submit Phase II report
Gantt Chart
Team progress• Finished debugging spreadsheet• Updated stream tables• Updated PFD• Finalizing individual design projects• Finalizing FEMA analysis
Facility layout• Color-coded rooms• Clean steam, WFI, air, O2, CO2 lines• Waste lines and neutralization tanks• Additional holding tanks• Personnel support space• Sized raw material and product warehouse• Added personnel and material flow arrows
Facility layout
Chromatography columns• Finalized chromatography column parameters• Determined pump, pipe, and valve requirements
Chromatography column results Criteria Protein A IEX HIC
Resin MabSelect Sepharose FFPhenyl
Sepharose6 FF (high sub)
Number 2 2 2Diameter [cm] 80 100 100
Flow Rate [cm/hr] 100 100 100
Average Process Time [hr]
27.4 9.5 27.5
Pump and pipe specifications
Pump Pipe
Type Positive Displacement Material Stainless
Steel
Power [hp] 1 Diameter [cm] 13
Capacity [L/min] 45.42 Unit Cost [$/1.5m] 100
Unit Price [$] 8,500 Pipeline Distance
[m] 769
Number 14 Number of Valves 53
Scheduling• Optimization of scheduling complete• Results:
Optimized scheduling details
Criteria Value Comment
Number of seed train rooms 2
Increases flexibility/reduced
operating time
Downstream lot size 31,000 L
Upstream train number 6
Labor scheduling
Position Number of personnelSeed train room 2 per roomBioreactor room 2 per roomMedia production 2Downstream process 2 per downstream processMixing buffer solution 2Autoclave operation 2WFI system 2Shift mananager Seed train 1 Bioreactor 1 Primary recovery 1 Chromatography/TFF 1
Water for injection• Compiled equipment inventory• Calculated equipment and operating costs• Added and sized holding tanks• Determined pump types and number• Sized and priced deionization unit
Equipment type and costEquipment Type Number Cost [$]
Clean steam generator Steris 450-T 1 97500
Deionization unit Siemens FlexTrex36 1 30355
Holding tanks Stainless steel 2 37078
Pumps Peristaltic Hose 4 25400
Vapor compression unit Stilmas 4700-T 2 1900000Total: 2090334
Water for injection
Major results• Process design and optimization completed• Individual and Phase II reports nearing completion• Economic analysis over 30 year plant life:
0 5 10 15 20 25 300
5,000,000,000
10,000,000,000
15,000,000,000
20,000,000,000
Discounted future profit
Plant lifetime [years]
Economic analysis Parameter Basecase Disposable
Fixed Capital Investment [billion $] 0.13 0.09Total Operating Costs [billion $] 9.1 8.94NPV [billion $] 158EACF [billion $] 8.0Future Worth of Profit [billion $] 383
Future goals• Redesign facility layout for optimized case• Separate number of seed trains from number
of bioreactors.• Set up seed train to handle arbitrary volume /
cell sizes.• Prepare for presentation• Rest
Questions?
Team Questions• Any other economic factors to consider aside
from HVAC costs?• Does my ethics report grade affect my team’s
overall score?