<strong>Deactivation test on catalysts</strong></br>Case Study

Deactivation test on catalysts
Case Study

Industrial Biotechnlogy, Specialty Chemicals, Oil and Gas, Natural Ingredients, Fine Chemicals
  PROJECT DESCRIPTION Our customer wishes to know the kinetic of deactivation of its catalyst under industrial conditions in order to adapt the sizing of corresponding process accordingly. In addition to this, the definition of the frequency of replacement of the catalyst was also an issue to secure productivity. TECHNICAL CHALLENGES Test should be performed continuously over hundreds of hours on a reactive mixture under conditions which precisely represent the operating conditions (temperatures over 250°C and pressures of 6 bar). The test needed to implement a dedicated bench to test the catalyst in continuous mode. OUR METHODOLOGY Design and development of a continuous reaction bench equipped with a tubular reactor working in conditions close to those of the process (6 bar and 250°C). Regular sampling from the reactor for 30 days.…
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Case study: Production of large organic acids sample

Case study: Production of large organic acids sample

Industrial Biotechnlogy
PROJECT DESCRIPTION A Client developed a bacteria which converts raw materials into organic acids and Processium designed and developed the process for DSP. First samples were produced at laboratory scale (around 100 mL) at Processium premises but 10 L were requested to allow the end-user to continue testing the bio-sourced product. To obtain this quantity, the amount of raw material is around 1 m3 which is too high regarding Processium equipment capacities. OUR METHODOLOGY Processium identified several potential sub-contractors for each step of the process. Meetings were organized with the Client to compare the sub-contractors (availability, technical level, flexibility, price) sub-contractors were chosen bythe client. Processium wrote the production protocol and took part to the trial both to ensure the protocol was applied correctly and to capitalize information regarding product behavior and process performances.…
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Case study: Production of a light chemical sample extracted from biogas

Case study: Production of a light chemical sample extracted from biogas

Industrial Biotechnlogy
PROJECT DESCRIPTION A Client developed a bacteria which converts sugar into light chemical and Processium designed and developed the process for DSP. In order to supply samples to potential end-users, 40 kg of purified product (extracted from pressurized gases) have to be produced y Processium on its own equipment. OUR METHODOLOGY Laboratory production is simulated to optimize operating conditions and reduce time for sample production. Distillation of raw material is carried out by Processium in its own laboratory: column efficiency is 20 theoretical stages, and pressure is 4 bar. RESULTS 40 kg of purified (99.7%) gas was produced.
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Case study: Design and development of a sustainable industrial separation and purification process of a molecule produced by fermentation

Case study: Design and development of a sustainable industrial separation and purification process of a molecule produced by fermentation

Industrial Biotechnlogy
PROJECT DESCRIPTION For a biotechnology company, Processium designed and developed a sustainable process to separate and purify a molecule produced by fermentation. Processium committed to execute its development within a very short period of time. The development of this process was intended to maximise the productivity of the molecule while ensuring high product quality and purity. TECHNICAL CHALLENGES This project was full of technical challenges: Undefined physical and chemical data. Complex rheology of the product. Client request not to use organic solvents. OUR METHODOLOGY Processium carried out a complete process development study starting from the definition of process specifications to issue of the process book: Measurement and analysis of key data (physical properties and thermodynamic parameters). Research of sustainable process technologies on the basis of the state of the art, our…
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Case study: Design of a purification process in the very early stages of the project, in the same time than fermentation process

Case study: Design of a purification process in the very early stages of the project, in the same time than fermentation process

Industrial Biotechnlogy
PROJECT DESCRIPTION Our client wishes to anticipate the DSP design studies by developing it in same time than the development of the strain used in the fermentation process. This methodology has allowed the customer to build its pilot plant and start the first pilot scale production right after the end of strain optimization. TECHNICAL CHALLENGES The technical challenge of this project was to start in the very early stages of the project: the study was realized before the achievement of the performances targeted in fermentation. Some parameters are unknown (impurities profile, concentration of main product, targeted industrial capacity, etc.). OUR METHODOLOGY Processium conducted the complete study from the identification of the technologies right up to the start-up of the industrial unit: Search of technological solutions: design and comparison of processes Development of the…
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Case study: Design of an industrial extraction process of molecules contained in micro-algae

Case study: Design of an industrial extraction process of molecules contained in micro-algae

Industrial Biotechnlogy
PROJECT DESCRIPTION On behalf of a biotech Company active on micro-algae fermentation technology, Processium designed and developed a separation and purification process for a molecule of interest dedicated to nutraceutical markets. This process shall be sufficient to meet very strict purity specifications (purity>99%) while minimizing CAPEX and OPEX. TECHNICAL CHALLENGES The technical challenges of this project were: The targeted molecule is in intra cellular into the micro-algae. Thermal sensitivity of the targeted molecule. Specific behavior of micro-algae during collecting: high viscosity of concentrated micro-algae. OUR METHODOLOGY Processium carried out this study starting from the definition of project specifications to the design corresponding process: Definition of specifications. Full study of technological solutions for the different steps of the process: Collection of micro-algae. Biomass drying process. Micro-algae cells lysis. Purification of the product…
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Case study: Development of a solvent extraction process

Case study: Development of a solvent extraction process

Industrial Biotechnlogy
PROJECT DESCRIPTION The Client is producing renewable oil for 2G fuels using sugar as raw material. Processium assisted the client in designing the desired process to the industrial scale with the objective of maximizing the yield in the extraction step while minimizing CAPEX and OPEX. TECHNICAL CHALLENGES The technical challenges in this project were: Target product molecule contained inside the microorganism? Non existing physic-chemical data, Undefined extraction solvent. OUR METHODOLOGY Processium carried out a complete process development study starting from the development of the design basis to the issue of the process book of this extraction unit: Measurement and analysis of key data (physical properties and thermodynamic parameters). Research of best available solvents into Processium solvents database in order to make a short-list of solvents to be tested at lab scale and…
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Case study: Economic feasibility evaluation for an  API manufactured through biotechnology process

Case study: Economic feasibility evaluation for an API manufactured through biotechnology process

Industrial Biotechnlogy
PROJECT DESCRIPTION The Client is producing API using biotechnology processes. At a laboratory scale, Client develop required GMO for the production of a new product. On the basis of this proof of concept that biological pathway exists, Process has developed a methodology to define specifications required for the economic and technical validation of industrial production of this new product. OUR METHODOLOGY On the basis of its internal know-how on such a Project, Processium is able: to develop a preliminary process flow-sheet for requested down-stream process, to define with the Client the hypothesis in term of product productivity, purity, etc., to evualuate globally the economic impact of fermentation performances by the identification of the key parameters influencing economics. RESULTS The development of such a methodology allows Processium: to identify critical parameters regarding technical performances,…
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Case study: Technical and economic impact on DSP following the change of microbes used for fermentation

Case study: Technical and economic impact on DSP following the change of microbes used for fermentation

Industrial Biotechnlogy
PROJECT DESCRIPTION The Client is producing GMO microbes for industrial biotechnology market. The Project is to develop a methodology to be able to anticipate impacts of the new strains on existing down-stream process and the benefits brought by the said strains in term of production efficiency in comparaison with strain actually used on the existing process. OUR METHODOLOGY On the basis of available data on existing process (PFD, mass balance, operating conditions and sizing of process equipment, physical properties, etc), Processium is able to: to develop physical properties modeling, to simulate existing processium in order to validate mass and thermal balance, to simulate process using new strains which lead to different fermentation performances and different broth composition, to estimate and compare OPEX (and CAPEX if requested) of both processes, to identify key parameters on strain…
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Case study: Technical and economic study for the production of organic acids

Case study: Technical and economic study for the production of organic acids

Industrial Biotechnlogy
  PROJECT DESCRIPTION The Client is developing a fermentation pathway to produce organic acids at a laboratory scale. On a basis of a theoritical and preliminary down-stream process, the Client request is to estimate the economic viability of its Project to reinforced its arguments towards potential financers. Included in its study, Processium also evaluates the impact of several hypothesis in term of technologies and products mix. OUR METHODOLOGY On the basis of data obtained through lab-scale experiments by the Client, Processium carries out this study to define: Preliminary process design based on Processium expertise, Preliminary sizing of the down-stream process. Several sizing calculations are conducted to anticipate miscellaneous hypothesis (concentration of the main product in fermentation broth, extraction yield depending on solvent, rate of preliminary concentration, recycling rate to the fermentor, annual capacity…
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