1
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Scholz BX, Hayashi Y, Udugama IA, Kino-oka M, Sugiyama H. A CFD model-based design of seeding processes for two-dimensional mesenchymal stem cell cultivation. Comput Chem Eng 2023. [DOI: 10.1016/j.compchemeng.2023.108157] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/30/2023]
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2
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Mancini E, Dickson R, Fabbri S, Udugama IA, Ullah HI, Vishwanath S, Gernaey KV, Luo J, Pinelo M, Mansouri SS. Corrigendum to ‘Economic and environmental analysis of bio-succinic acid production: From established processes to a new continuous fermentation approach with in-situ electrolytic extraction’ [Chemical Engineering Research and Design Volume 179, March 2022, Pages 401–414]. Chem Eng Res Des 2022. [DOI: 10.1016/j.cherd.2022.06.043] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/03/2022]
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3
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Scholz BX, Hayashi Y, Udugama IA, Kino-oka M, Sugiyama H. A multilayered approach to scale-up forced convection-based freezing of human induced pluripotent stem cells. Comput Chem Eng 2022. [DOI: 10.1016/j.compchemeng.2022.107851] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
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4
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Hartmann FSF, Udugama IA, Seibold GM, Sugiyama H, Gernaey KV. Digital models in biotechnology: Towards multi-scale integration and implementation. Biotechnol Adv 2022; 60:108015. [PMID: 35781047 DOI: 10.1016/j.biotechadv.2022.108015] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/14/2022] [Revised: 06/03/2022] [Accepted: 06/27/2022] [Indexed: 12/28/2022]
Abstract
Industrial biotechnology encompasses a large area of multi-scale and multi-disciplinary research activities. With the recent megatrend of digitalization sweeping across all industries, there is an increased focus in the biotechnology industry on developing, integrating and applying digital models to improve all aspects of industrial biotechnology. Given the rapid development of this field, we systematically classify the state-of-art modelling concepts applied at different scales in industrial biotechnology and critically discuss their current usage, advantages and limitations. Further, we critically analyzed current strategies to couple cell models with computational fluid dynamics to study the performance of industrial microorganisms in large-scale bioprocesses, which is of crucial importance for the bio-based production industries. One of the most challenging aspects in this context is gathering intracellular data under industrially relevant conditions. Towards comprehensive models, we discuss how different scale-down concepts combined with appropriate analytical tools can capture intracellular states of single cells. We finally illustrated how the efforts could be used to develop digitals models suitable for both cell factory design and process optimization at industrial scales in the future.
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Affiliation(s)
- Fabian S F Hartmann
- Department of Biotechnology and Biomedicine, Technical University of Denmark, Søltofts Plads, Building 223, 2800 Kgs. Lyngby, Denmark
| | - Isuru A Udugama
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1, Hongo, Bunkyo-ku, 113-8656 Tokyo, Japan; Department of Chemical and Biochemical Engineering, Technical University of Denmark, Søltofts Plads, Building 228 A, 2800 Kgs. Lyngby, Denmark.
| | - Gerd M Seibold
- Department of Biotechnology and Biomedicine, Technical University of Denmark, Søltofts Plads, Building 223, 2800 Kgs. Lyngby, Denmark
| | - Hirokazu Sugiyama
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1, Hongo, Bunkyo-ku, 113-8656 Tokyo, Japan
| | - Krist V Gernaey
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, Søltofts Plads, Building 228 A, 2800 Kgs. Lyngby, Denmark.
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5
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Hirono K, A. Udugama I, Hayashi Y, Kino-oka M, Sugiyama H. A Dynamic and Probabilistic Design Space Determination Method for Mesenchymal Stem Cell Cultivation Processes. Ind Eng Chem Res 2022. [DOI: 10.1021/acs.iecr.2c00374] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Keita Hirono
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan
| | - Isuru A. Udugama
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan
| | - Yusuke Hayashi
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan
| | - Masahiro Kino-oka
- Department of Biotechnology, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan
| | - Hirokazu Sugiyama
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan
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6
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Mancini E, Dickson R, Fabbri S, Udugama IA, Ullah HI, Vishwanath S, Gernaey KV, Luo J, Pinelo M, Mansouri SS. Economic and environmental analysis of bio-succinic acid production: From established processes to a new continuous fermentation approach with in-situ electrolytic extraction. Chem Eng Res Des 2022. [DOI: 10.1016/j.cherd.2022.01.040] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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7
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Martínez-Monge I, Martínez C, Decker M, Udugama IA, Marín de Mas I, Gernaey KV, Nielsen LK. Soft-sensors application for automated feeding control in high-throughput mammalian cell cultures. Biotechnol Bioeng 2022; 119:1077-1090. [PMID: 35005786 DOI: 10.1002/bit.28032] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/18/2021] [Revised: 01/03/2022] [Accepted: 01/04/2022] [Indexed: 11/07/2022]
Abstract
The ever-increasing demand for biopharmaceuticals has created the need for improving the overall productivity of culture processes. One such operational concept that is considered is fed-batch operations as opposed to batch operations. However, optimal fed-batch operations require complete knowledge of the cell culture to optimize the culture conditions and the nutrients feeding. For example, when using high-throughput small-scale bioreactors to test multiple clones that do not behave the same, depletion or overfeeding of some key components can occur if the feeding strategy is not individually optimized. Over the recent years, various solutions for real-time measuring of the main cell culture metabolites have been proposed. Still, the complexity in the implementation of these techniques has limited their use. Soft-sensors present an opportunity to overcome these limitations by indirectly estimate these variables in real-time. This manuscript details the development of a new soft-sensor based fed-batch strategy to maintain substrate concentration (glucose and glutamine) at optimal levels in small-scale multi parallel CHO cultures. Two alternatives to the standard feeding strategy were tested: an OUR soft-sensor-based strategy for glucose and glutamine (Strategy 1) and a dual OUR for glutamine and CO2 /alkali addition for glucose soft-sensor strategy (Strategy 2). The results demonstrated the applicability of the OUR soft-sensor based strategy to optimize glucose and glutamine feedings, which yielded a 21% increase in final viable cell density (VCD) and a 31% in erythropoietin (EPO) titer compared with the reference one. However, CO2/alkali addition soft-sensor suffered from insufficient data to relate alkali addition with glucose consumption. As a result, the culture was overfed with glucose resulting in a 4% increase on final VCD, but a 9% decrease in final titer compared to the Reference Strategy. This article is protected by copyright. All rights reserved.
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Affiliation(s)
- I Martínez-Monge
- The Novo Nordisk Foundation Center for Biosustainability, Technical University of Denmark, DK-2800, Kongens, Lyngby, Denmark
| | - C Martínez
- The Novo Nordisk Foundation Center for Biosustainability, Technical University of Denmark, DK-2800, Kongens, Lyngby, Denmark
| | - M Decker
- The Novo Nordisk Foundation Center for Biosustainability, Technical University of Denmark, DK-2800, Kongens, Lyngby, Denmark
| | - I A Udugama
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, DK-2800, Kongens, Lyngby, Denmark
| | - I Marín de Mas
- The Novo Nordisk Foundation Center for Biosustainability, Technical University of Denmark, DK-2800, Kongens, Lyngby, Denmark
| | - K V Gernaey
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, DK-2800, Kongens, Lyngby, Denmark
| | - L K Nielsen
- The Novo Nordisk Foundation Center for Biosustainability, Technical University of Denmark, DK-2800, Kongens, Lyngby, Denmark
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Yamada M, Badr S, Udugama IA, Fukuda S, Nakaya M, Yoshioka Y, Sugiyama H. A systematic techno-economic approach to decide between continuous and batch operation modes for injectable manufacturing. Int J Pharm 2021; 613:121353. [PMID: 34896214 DOI: 10.1016/j.ijpharm.2021.121353] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/08/2021] [Revised: 11/08/2021] [Accepted: 12/02/2021] [Indexed: 12/23/2022]
Abstract
A comprehensive approach is proposed to systematically determine the optimal mode of operation between continuous and batch injectable manufacturing considering product and market conditions. At the core of this approach are two integrated complete mathematical modules for discrete and continuous injectable manufacturing, which are supplemented with an economic evaluation module that can then be used to explore the impact of all relevant process parameters (e.g., lot-size, number of operators, solubility, product demand, raw material costs). When the developed approach was applied to two case studies, it was found that batch production was preferred at low to moderate solution (raw material) costs. In contrast, at higher solution costs, the preference for batch and continuous production processes changed back and forth as the annual product demand changed. The study also found that continuous production processes became increasingly preferred at medium to large final dosage volumes and a competitive alternative even at moderate solution costs. From a decision-making point of view, batch injectable manufacturing will be preferred over the novel continuous manufacturing technology unless there is a significant economic incentive to overcome the perceived technology risk. The proposed approach is intended as a decision-support tool for pharmaceutical process engineers.
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Affiliation(s)
- Masahiro Yamada
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1, Hongo, Bunkyo-ku, 113-8656 Tokyo, Japan
| | - Sara Badr
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1, Hongo, Bunkyo-ku, 113-8656 Tokyo, Japan
| | - Isuru A Udugama
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1, Hongo, Bunkyo-ku, 113-8656 Tokyo, Japan
| | - Shouko Fukuda
- Settsu Plant, Shionogi Pharma Co., Ltd., 2-5-1, Mishima, Settsu-Shi, 556-0022 Osaka, Japan
| | - Manabu Nakaya
- Settsu Plant, Shionogi Pharma Co., Ltd., 2-5-1, Mishima, Settsu-Shi, 556-0022 Osaka, Japan
| | - Yasuyuki Yoshioka
- Settsu Plant, Shionogi Pharma Co., Ltd., 2-5-1, Mishima, Settsu-Shi, 556-0022 Osaka, Japan
| | - Hirokazu Sugiyama
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1, Hongo, Bunkyo-ku, 113-8656 Tokyo, Japan.
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Ngo PL, Udugama IA, Gernaey KV, Young BR, Baroutian S. Mechanisms, status, and challenges of thermal hydrolysis and advanced thermal hydrolysis processes in sewage sludge treatment. Chemosphere 2021; 281:130890. [PMID: 34023763 DOI: 10.1016/j.chemosphere.2021.130890] [Citation(s) in RCA: 26] [Impact Index Per Article: 8.7] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/03/2021] [Revised: 04/30/2021] [Accepted: 05/07/2021] [Indexed: 06/12/2023]
Abstract
Sewage sludge management has garnered interest in both academia and industry due to the challenges of overpopulation and its potential as a bioenergy source. Thermal hydrolysis is a promising technology for sludge pre-treatment prior to anaerobic digestion to enhance biogas production. However, the technology is facing two main problems; the dark colour of sludge can affect UV disinfection and the formation of methanogenesis inhibitors such as free ammonia and refractory compounds have a significant impact on methane production in anaerobic digestion processes. Advanced thermal hydrolysis, which is an oxidative thermal hydrolysis process, has been introduced to overcome these challenges. This study provides a comprehensive review of the mechanisms and reactions which occur during the hydrothermal hydrolysis and advanced thermal hydrolysis processes. Technical and implementation challenges of both technologies are discussed. Additionally, the prospects of the technologies are assessed through their technology readiness levels. An assessment of the relevant literature is also provided to illuminate the aspects in which research gaps exist and areas where additional studies could be performed.
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Affiliation(s)
- Phuong Linh Ngo
- Department of Chemical and Materials Engineering, The University of Auckland, Auckland, 1010, New Zealand; Department of Environmental Engineering, The Institute of Biotechnology and Environment, Nha Trang University, Viet Nam
| | - Isuru A Udugama
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, Denmark
| | - Krist V Gernaey
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, Denmark
| | - Brent R Young
- Department of Chemical and Materials Engineering, The University of Auckland, Auckland, 1010, New Zealand
| | - Saeid Baroutian
- Department of Chemical and Materials Engineering, The University of Auckland, Auckland, 1010, New Zealand.
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10
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A. Udugama I, Öner M, Lopez PC, Beenfeldt C, Bayer C, Huusom JK, Gernaey KV, Sin G. Towards Digitalization in Bio-Manufacturing Operations: A Survey on Application of Big Data and Digital Twin Concepts in Denmark. Front Chem Eng 2021. [DOI: 10.3389/fceng.2021.727152] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/13/2022] Open
Abstract
Digitalization in the form of Big Data and Digital Twin inspired applications are hot topics in today's bio-manufacturing organizations. As a result, many organizations are diverting resources (personnel and equipment) to these applications. In this manuscript, a targeted survey was conducted amongst individuals from the Danish biotech industry to understand the current state and perceived future obstacles in implementing digitalization concepts in biotech production processes. The survey consisted of 13 questions related to the current level of application of 1) Big Data analytics and 2) Digital Twins, as well as obstacles to expanding these applications. Overall, 33 individuals responded to the survey, a group spanning from bio-chemical to biopharmaceutical production. Over 73% of the respondents indicated that their organization has an enterprise-wide level plan for digitalization, it can be concluded that the digitalization drive in the Danish biotech industry is well underway. However, only 30% of the respondents reported a well-established business case for the digitalization applications in their organization. This is a strong indication that the value proposition for digitalization applications is somewhat ambiguous. Further, it was reported that digital twin applications (58%) were more widely used than Big Data analytic tools (37%). On top of the lack of a business case, organizational readiness was identified as a critical hurdle that needs to be overcome for both Digital Twin and Big Data applications. Infrastructure was another key hurdle for implementation, with only 6% of the respondents stating that their production processes were 100% covered by advanced process analytical technologies.
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11
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Sánchez-Ramírez E, Segovia-Hernandez JG, Lund NL, Pinto T, Udugama IA, Junicke H, Mansouri SS. Sustainable Purification of Butanol from a Class of a Mixture Produced by Reduction of Volatile Fatty Acids. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.0c06164] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Eduardo Sánchez-Ramírez
- Departamento de Ingeniería Química, Universidad de Guanajuato, Campus Guanajuato,
Noria Alta s/n, Guanajuato Gto. 36050, México
| | - Juan Gabriel Segovia-Hernandez
- Departamento de Ingeniería Química, Universidad de Guanajuato, Campus Guanajuato,
Noria Alta s/n, Guanajuato Gto. 36050, México
| | - Nicklas Leander Lund
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, Søltofts Pldas, Building 228A, Kongens Lyngby, Lyngby 2800, Denmark
| | - Tiago Pinto
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, Søltofts Pldas, Building 228A, Kongens Lyngby, Lyngby 2800, Denmark
| | - Isuru A. Udugama
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, Søltofts Pldas, Building 228A, Kongens Lyngby, Lyngby 2800, Denmark
| | - Helena Junicke
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, Søltofts Pldas, Building 228A, Kongens Lyngby, Lyngby 2800, Denmark
| | - Seyed Soheil Mansouri
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, Søltofts Pldas, Building 228A, Kongens Lyngby, Lyngby 2800, Denmark
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12
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Cabaneros Lopez P, Udugama IA, Thomsen ST, Roslander C, Junicke H, Iglesias MM, Gernaey KV. Transforming data to information: A parallel hybrid model for real-time state estimation in lignocellulosic ethanol fermentation. Biotechnol Bioeng 2020; 118:579-591. [PMID: 33002188 PMCID: PMC7894558 DOI: 10.1002/bit.27586] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/21/2020] [Revised: 09/17/2020] [Accepted: 09/26/2020] [Indexed: 11/21/2022]
Abstract
Operating lignocellulosic fermentation processes to produce fuels and chemicals is challenging due to the inherent complexity and variability of the fermentation media. Real‐time monitoring is necessary to compensate for these challenges, but the traditional process monitoring methods fail to deliver actionable information that can be used to implement advanced control strategies. In this study, a hybrid‐modeling approach is presented to monitor cellulose‐to‐ethanol (EtOH) fermentations in real‐time. The hybrid approach uses a continuous‐discrete extended Kalman filter to reconciliate the predictions of a data‐driven model and a kinetic model and to estimate the concentration of glucose (Glu), xylose (Xyl), and EtOH. The data‐driven model is based on partial least squares (PLS) regression and predicts in real‐time the concentration of Glu, Xyl, and EtOH from spectra collected with attenuated total reflectance mid‐infrared spectroscopy. The estimations made by the hybrid approach, the data‐driven models and the internal model were compared in two validation experiments showing that the hybrid model significantly outperformed the PLS and improved the predictions of the internal model. Furthermore, the hybrid model delivered consistent estimates even when disturbances in the measurements occurred, demonstrating the robustness of the method. The consistency of the proposed hybrid model opens the doors towards the implementation of advanced feedback control schemes.
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Affiliation(s)
- Pau Cabaneros Lopez
- Department of Chemical and Biochemical Engineering, Process and Systems Engineering Center (PROSYS), Technical University of Denmark (DTU), Lyngby, Denmark
| | - Isuru A Udugama
- Department of Chemical and Biochemical Engineering, Process and Systems Engineering Center (PROSYS), Technical University of Denmark (DTU), Lyngby, Denmark
| | - Sune T Thomsen
- Department of Geosciences and Natural Resource Management, University of Copenhagen, Frederiksberg, Denmark
| | | | - Helena Junicke
- Department of Chemical and Biochemical Engineering, Process and Systems Engineering Center (PROSYS), Technical University of Denmark (DTU), Lyngby, Denmark
| | - Miguel M Iglesias
- Department of Chemical Engineering, CRETUS Institute, Universidade de Santiago de Compostela, Santiago de Compostela, Spain
| | - Krist V Gernaey
- Department of Chemical and Biochemical Engineering, Process and Systems Engineering Center (PROSYS), Technical University of Denmark (DTU), Lyngby, Denmark
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13
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Udugama IA, Kirkpatrick R, Yu W, Gernaey KV, Young BR, Bayer C. Separation of middle boiling trace compounds by distillation: An investigation of practical implications of complex column arrangements on an industrial methanol distillation case study. ASIA-PAC J CHEM ENG 2020. [DOI: 10.1002/apj.2588] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
Affiliation(s)
- Isuru A. Udugama
- Process and Systems Engineering Center (PROSYS), Department of Chemical and Biochemical Engineering Technical University of Denmark Kongens Lyngby Denmark
- Department of Chemical and Materials Engineering University of Auckland Auckland New Zealand
| | - Robert Kirkpatrick
- Department of Chemical and Materials Engineering University of Auckland Auckland New Zealand
| | - Wei Yu
- Department of Chemical and Materials Engineering University of Auckland Auckland New Zealand
| | - Krist V. Gernaey
- Process and Systems Engineering Center (PROSYS), Department of Chemical and Biochemical Engineering Technical University of Denmark Kongens Lyngby Denmark
| | - Brent R. Young
- Department of Chemical and Materials Engineering University of Auckland Auckland New Zealand
| | - Christoph Bayer
- Department of Process Engineering TH Nuernberg Nuernberg Germany
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14
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Nazemzadeh N, Udugama IA, Karcz AP, Andersson MP, Abildskov J, Mansouri SS. Molecular tracking: A concept for side‐draw distillation column design. AIChE J 2020. [DOI: 10.1002/aic.17070] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022]
Affiliation(s)
- Nima Nazemzadeh
- Department of Chemical and Biochemical Engineering Technical University of Denmark Kgs. Lyngby Denmark
| | - Isuru A. Udugama
- Department of Chemical and Biochemical Engineering Technical University of Denmark Kgs. Lyngby Denmark
| | - Adam Paul Karcz
- Department of Chemical and Biochemical Engineering Technical University of Denmark Kgs. Lyngby Denmark
| | - Martin Peter Andersson
- Department of Chemical and Biochemical Engineering Technical University of Denmark Kgs. Lyngby Denmark
| | - Jens Abildskov
- Department of Chemical and Biochemical Engineering Technical University of Denmark Kgs. Lyngby Denmark
| | - Seyed Soheil Mansouri
- Department of Chemical and Biochemical Engineering Technical University of Denmark Kgs. Lyngby Denmark
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15
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Udugama IA, Gargalo CL, Yamashita Y, Taube MA, Palazoglu A, Young BR, Gernaey KV, Kulahci M, Bayer C. The Role of Big Data in Industrial (Bio)chemical Process Operations. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.0c01872] [Citation(s) in RCA: 28] [Impact Index Per Article: 7.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Isuru A. Udugama
- Process and Systems Engineering Center (PROSYS), Department of Chemical and Biochemical Engineering, Technical University of Denmark, Kongens Lyngby, 2800, Denmark
| | - Carina L. Gargalo
- Process and Systems Engineering Center (PROSYS), Department of Chemical and Biochemical Engineering, Technical University of Denmark, Kongens Lyngby, 2800, Denmark
| | - Yoshiyuki Yamashita
- Department of Chemical Engineering, Tokyo University of Agriculture and Technology, Koganei, Tokyo, 184-9599, Japan
| | | | - Ahmet Palazoglu
- Department of Chemical Engineering, University of California, Davis, California 95616, United States
| | - Brent R. Young
- Industrial Information and Control Centre, Department of Chemical & Materials Engineering, The University of Auckland, Auckland, 1010, New Zealand
| | - Krist V. Gernaey
- Process and Systems Engineering Center (PROSYS), Department of Chemical and Biochemical Engineering, Technical University of Denmark, Kongens Lyngby, 2800, Denmark
| | - Murat Kulahci
- Department of Applied Mathematics and Computer Science, Technical University of Denmark, Kongens Lyngby, 2800, Denmark
- Department of Business Administration, Technology and Social Sciences, Luleå University of Technology, Luleå, 97817, Sweden
| | - Christoph Bayer
- Department of Process Engineering, TH Nürnberg, Nürnberg, 90489, Germany
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Gani R, Bałdyga J, Biscans B, Brunazzi E, Charpentier JC, Drioli E, Feise H, Furlong A, Van Geem KM, de Hemptinne JC, ten Kate AJ, Kontogeorgis GM, Manenti F, Marin GB, Mansouri SS, Piccione PM, Povoa A, Rodrigo MA, Sarup B, Sorensen E, Udugama IA, Woodley JM. A multi-layered view of chemical and biochemical engineering. Chem Eng Res Des 2020. [DOI: 10.1016/j.cherd.2020.01.008] [Citation(s) in RCA: 48] [Impact Index Per Article: 12.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/04/2023]
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17
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Ang TN, Udugama IA, Mansouri SS, Taylor M, Burrell R, Young BR, Baroutian S. A techno-economic-societal assessment of recovery of waste volatile anaesthetics. Sep Purif Technol 2019. [DOI: 10.1016/j.seppur.2019.06.011] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
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18
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A. Udugama I, Alvarez Camps M, Taube MA, Thawita C, Anantpinijwatna A, Mansouri SS, Young BR, Yu W. Novel Soft Sensor for Measuring and Controlling Product Recovery in a High-Purity, Multicomponent, Side-Draw Distillation Column. Ind Eng Chem Res 2019. [DOI: 10.1021/acs.iecr.9b04594] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Isuru A. Udugama
- Process and Systems Engineering Center (PROSYS), Department of Chemical and Biochemical Engineering, Technical University of Denmark, Lyngby 2800, Denmark
| | - Martina Alvarez Camps
- Process and Systems Engineering Center (PROSYS), Department of Chemical and Biochemical Engineering, Technical University of Denmark, Lyngby 2800, Denmark
| | | | - Chatchayarat Thawita
- Department of Chemical Engineering, Faculty of Engineering, King Mongkut’s Institute of Technology Ladkrabang, Chalongkrung Road, Ladkrabang 10520, Thailand
| | - Amata Anantpinijwatna
- Department of Chemical Engineering, Faculty of Engineering, King Mongkut’s Institute of Technology Ladkrabang, Chalongkrung Road, Ladkrabang 10520, Thailand
| | - Seyed Soheil Mansouri
- Process and Systems Engineering Center (PROSYS), Department of Chemical and Biochemical Engineering, Technical University of Denmark, Lyngby 2800, Denmark
| | - Brent R. Young
- Department of Chemical & Materials Engineering, The University of Auckland, Auckland 1142, New Zealand
| | - Wei Yu
- Department of Chemical & Materials Engineering, The University of Auckland, Auckland 1142, New Zealand
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Udugama IA, Taube MA, Mansouri SS, Kirkpatrick R, Gernaey KV, Yu W, Young BR. A Systematic Methodology for Comprehensive Economic Assessment of Process Control Structures. Ind Eng Chem Res 2018. [DOI: 10.1021/acs.iecr.8b01883] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Isuru A. Udugama
- Department of Chemical & Materials Engineering, University of Auckland, Auckland, 1010, New Zealand
| | | | - Seyed Soheil Mansouri
- Process and Systems Engineering Centre (PROSYS), Department of Chemical and Biochemical Engineering, Technical University of Denmark, DK-2800 Kgs. Lyngby, Denmark
| | - Robert Kirkpatrick
- Department of Chemical & Materials Engineering, University of Auckland, Auckland, 1010, New Zealand
| | - Krist V. Gernaey
- Process and Systems Engineering Centre (PROSYS), Department of Chemical and Biochemical Engineering, Technical University of Denmark, DK-2800 Kgs. Lyngby, Denmark
| | - Wei Yu
- Department of Chemical & Materials Engineering, University of Auckland, Auckland, 1010, New Zealand
| | - Brent R. Young
- Department of Chemical & Materials Engineering, University of Auckland, Auckland, 1010, New Zealand
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A Udugama I, Munir MT, Kirkpatrick R, Young BR, Yu W. Side draw control design for a high purity multi-component distillation column. ISA Trans 2018; 76:167-177. [PMID: 29563020 DOI: 10.1016/j.isatra.2018.03.006] [Citation(s) in RCA: 12] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 01/26/2016] [Revised: 01/30/2018] [Accepted: 03/04/2018] [Indexed: 06/08/2023]
Abstract
Industrial methanol production involves a multi component feed containing methanol, water and trace levels of ethanol being refined to produce AA grade methanol at high product recovery. Due to practical constraints, the bottoms discharge of the column is primarily water with only trace of methanol impurities. As a result of these constraints, ethanol, which is a non-key middle boiling component gets "trapped" near the side draw of the column forming an ethanol bulge, which in turn results in non-linear, inverse, time and state varying behaviour of the side draw ethanol composition. In this work, we established that the existence of the ethanol bulge creates the complex process behaviour of the side draw ethanol composition and that this bulge needs to be explicitly controlled. This type of explicit composition bulge analysis and subsequent control has not been attempted on methanol distillation columns before. For this purpose a novel, robust and practical side draw control scheme to detect and remedy the excess ethanol bulge movement using override control is presented. The side draw controller, together with other regulatory controllers is shown to maintain on-specification operations of the column. Disturbance rejection tests carried out illustrate that the side draw control scheme will keep the column operating within commercial specification. It is also shown that a traditional DV control structure is unable to achieve this objective.
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Affiliation(s)
- Isuru A Udugama
- Chemical & Materials Engineering, The University of Auckland, New Zealand
| | - M T Munir
- Industrial Information and Control Centre, The University of Auckland, New Zealand
| | - Rob Kirkpatrick
- Chemical & Materials Engineering, The University of Auckland, New Zealand
| | - Brent R Young
- Chemical & Materials Engineering, The University of Auckland, New Zealand; Industrial Information and Control Centre, The University of Auckland, New Zealand
| | - Wei Yu
- Chemical & Materials Engineering, The University of Auckland, New Zealand; Industrial Information and Control Centre, The University of Auckland, New Zealand.
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Mansouri SS, Udugama IA, Cignitti S, Mitic A, Flores-Alsina X, Gernaey KV. Resource recovery from bio-based production processes: a future necessity? Curr Opin Chem Eng 2017. [DOI: 10.1016/j.coche.2017.06.002] [Citation(s) in RCA: 35] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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Udugama IA, Wolfenstetter F, Kirkpatrick R, Yu W, Young BR. A comparison of a novel robust decentralised control strategy and MPC for industrial high purity, high recovery, multicomponent distillation. ISA Trans 2017; 69:222-233. [PMID: 28416181 DOI: 10.1016/j.isatra.2017.04.008] [Citation(s) in RCA: 14] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/19/2016] [Revised: 01/19/2017] [Accepted: 04/10/2017] [Indexed: 06/07/2023]
Abstract
In this work we have developed a novel, robust practical control structure to regulate an industrial methanol distillation column. This proposed control scheme is based on a override control framework and can manage a non-key trace ethanol product impurity specification while maintaining high product recovery. For comparison purposes, a MPC with a discrete process model (based on step tests) was also developed and tested. The results from process disturbance testing shows that, both the MPC and the proposed controller were capable of maintaining both the trace level ethanol specification in the distillate (XD) and high product recovery (β). Closer analysis revealed that the MPC controller has a tighter XD control, while the proposed controller was tighter in β control. The tight XD control allowed the MPC to operate at a higher XD set point (closer to the 10ppm AA grade methanol standard), allowing for savings in energy usage. Despite the energy savings of the MPC, the proposed control scheme has lower installation and running costs. An economic analysis revealed a multitude of other external economic and plant design factors, that should be considered when making a decision between the two controllers. In general, we found relatively high energy costs favour MPC.
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Affiliation(s)
- Isuru A Udugama
- Chemical & Materials Engineering, The University of Auckland, New Zealand; Industrial Information and Control Centre, The University of Auckland, New Zealand
| | | | - Robert Kirkpatrick
- Chemical & Materials Engineering, The University of Auckland, New Zealand
| | - Wei Yu
- Chemical & Materials Engineering, The University of Auckland, New Zealand; Industrial Information and Control Centre, The University of Auckland, New Zealand
| | - Brent R Young
- Chemical & Materials Engineering, The University of Auckland, New Zealand; Industrial Information and Control Centre, The University of Auckland, New Zealand.
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