Case Study 4 - Startup

The analysis of throughput issues associated with a newly completed large scale microbial recombinant growth hormone manufacturing facility. Due to underestimation of the utility requirements, throughput was limited to less than 55% of the design capacity. The objective of the project was to develop an accurate process model to allow diagnosis of the cause(s), and the evaluation of remedial actions.

Aims & Objectives

  • Throughput analysis
  • Debottlenecking
  • Complete utility system simulation
  • Modelling of CIP system (incl. tank levels)
  • Diagnosis of productivity constraints
  • Evaluation of corrective options

Results

  • Accurate simulation of process bottlenecks
  • Simulation of utility system
       - Mean RO water usage rate prediction error <10%
       -     Mean PW usage rate prediction error <2.5%
  • Diagnosis of high CIP water usage
  • Analysis of proposed updates:
       -     Initial storage expansion insufficient
       -     Additional generation requirements determined