Processing scaling

Reversed-phase chromatography is widely used as an analytical tool for protein chromatography, but it is not as commonly found on a process scale for protein purification because the solvents which make up the mobile phase, ie, acetonitrile, isopropanol, methanol, and ethanol, reversibly or irreversibly denature proteins. Hydrophobic interaction chromatography appears to be the least common process chromatography tool, possibly owing to the relatively high costs of the salts used to make up the mobile phases. 

Column Si. Size-exclusion chromatography columns are generally the largest column on a process scale. Separation is based strictly on diffusion rates of the molecules inside the gel particles. No proteins or other solutes are adsorbed or otherwise retained owing to adsorption, thus, significant dilution of the sample of volume can occur, particularly for small sample volumes. The volumetric capacity of this type of chromatography is determined by the concentration of the proteins for a given volume of the feed placed on the column. 

Another example is the purification of a P-lactam antibiotic, where process-scale reversed-phase separations began to be used around 1983 when suitable, high pressure process-scale equipment became available. A reversed-phase microparticulate (55—105 p.m particle size) C g siUca column, with a mobile phase of aqueous methanol having 0.1 Af ammonium phosphate at pH 5.3, was able to fractionate out impurities not readily removed by hquid—hquid extraction (37). Optimization of the separation resulted in recovery of product at 93% purity and 95% yield. This type of separation differs markedly from protein purification in feed concentration ( i 50 200 g/L for cefonicid vs 1 to 10 g/L for protein), molecular weight of impurities (<5000 compared to 10,000—100,000 for proteins), and throughputs ( i l-2 mg/(g stationary phasemin) compared to 0.01—0.1 mg/(gmin) for proteins). 

Scale- Up of Electrochemical Reactors. The intermediate scale of the pilot plant is frequendy used in the scale-up of an electrochemical reactor or process to full scale. Dimensional analysis (qv) has been used in chemical engineering scale-up to simplify and generalize a multivariant system, and may be appHed to electrochemical systems, but has shown limitations. It is best used in conjunction with mathematical models. Scale-up often involves seeking a few critical parameters. Eor electrochemical cells, these parameters are generally current distribution and cell resistance. The characteristics of electrolytic process scale-up have been described (63—65). 

The final purification steps are responsible for the removal of the last traces of impurities. The volume reduction in the earlier stages of the separation train are necessarv to ensure that these high-resolution operations are not overloaded. Generally, chromatograjmy is used in these final stages. Electrophoresis can also be used, but since it is rarely found in process-scale operations, it is not addressed here. The final product preparation may require removal of solvent and drying, or lyophihzation, of the product. 

Figure 8.8 Precipitation process scale-up methodology after Zauner and Jones, 2000b)...

For the purpose of high-resolution fractionation, the gel medium must be tailor made to cope with different separation ranges. The Superdex family is designed for the high resolution of peptides and proteins having a molecular mass of 500 to 100,000. Also, Sephacryl media have found wide applicability as a final polishing step in process scale SEC (see Section III,C). 

A process scale application of Sephacryl S-100 is demonstrated by the polishing of a pharmaceutical in a system of three BPSS columns giving a final bed volume of 2500 liters (Fig. 2.9, page 51). 

Toyopearl HW size exclusion chromatography resins are macroporous packings for bioprocessing chromatography. They are applicable for process-scale... 

Toyopearl HW resins overcome several disadvantages of conventional gels, which do not function well at higher flow rates or pressures, are unstable to extremes of pH, salt, and organic solvent concentrations, and can leach saccharide derivatives into the process material. For process-scale SEC, Toyopearl HW resins provide the following advantages ... 

The hydrophilic surface characteristics and the chemical nature of the polymer backbone in Toyopearl HW resins are the same as for packings in TSK-GEL PW HPLC columns. Consequently, Toyopearl HW packings are ideal scaleup resins for analytical separation methods developed with TSK-GEL HPLC columns. Eigure 4.44 shows a protein mixture first analyzed on TSK-GEL G3000 SWxl and TSK-GEL G3000 PWxl columns, then purified with the same mobile-phase conditions in a preparative Toyopearl HW-55 column. The elution profile and resolution remained similar from the analytical separation on the TSK-GEL G3000 PWxl column to the process-scale Toyopearl column. Scaleup from TSK-GEL PW columns can be direct and more predictable with Toyopearl HW resins. 

Another important issue that must be considered in the development of CSPs for preparative separations is the solubility of enantiomers in the mobile phase. For example, the mixtures of hexane and polar solvents such as tetrahydrofuran, ethyl acetate, and 2-propanol typically used for normal-phase HPLC may not dissolve enough compound to overload the column. Since the selectivity of chiral recognition is strongly mobile phase-dependent, the development and optimization of the selector must be carried out in such a solvent that is well suited for the analytes. In contrast to analytical separations, separations on process scale do not require selectivity for a broad variety of racemates, since the unit often separates only a unique mixture of enantiomers. Therefore, a very high key-and-lock type selectivity, well known in the recognition of biosystems, would be most advantageous for the separation of a specific pair of enantiomers in large-scale production. 

These policy decisions by the FDA were the driving force for chiral switches and the commercial development of chromatographic processes such as simulated moving bed (SMB) technology. Due to technological advances such as SMB and the commercial availability of CSPs in bulk quantities for process-scale purification of enantiopure drugs, the production of many single enantiomers now exists on a commercial scale. 

The purification of value-added pharmaceuticals in the past required multiple chromatographic steps for batch purification processes. The design and optimization of these processes were often cumbersome and the operations were fundamentally complex. Individual batch processes requires optimization between chromatographic efficiency and enantioselectivity, which results in major economic ramifications. An additional problem was the extremely short time for development of the purification process. Commercial constraints demand that the time interval between non-optimized laboratory bench purification and the first process-scale production for clinical trials are kept to a minimum. Therefore, rapid process design and optimization methods based on computer aided simulation of an SMB process will assist at this stage. 

In spite of its wide application, the mechanisms of this reaction remain obscure. Many diverse arguments have been published since the reaction was first investigated in 1897 (Bl, C5, C9, F7, J6, M5, P9, R2, S5, W2, W4, Yl, Y4). Cooper et al. (C9) introduced this method as a yardstick for the measurement of volumetric mass-transfer coefficients in gas-liquid contacting. Karow et al. (Kl) later concluded that the sulfite oxidation is suitable for fermentation process scale-up studies. Cooper et al. established that the reaction proceeds at a rate independent of sulfite ion concentration over wide concentration ranges. In their work they considered the sulfite oxidation to be of zero order with respect to both sulfite and sulfate concentration. 

Changes in final process scale involving new equipment... 

Case study 4 Process scale up and resource efficiency of an industrial product... 

Ideally, a mathematical model would link yields and/or product properties with process variables in terms of fundamental process phenomena only. All model parameters would be taken from existing theories and there would be no need for adjusting parameters. Such models would be the most powerful at extrapolating results from small scale to a full process scale. The models with which we deal in practice do never reflect all the microscopic details of all phenomena composing the process. Therefore, experimental correlations for model parameters are used and/or parameters are evaluated by fitting the calculated process performance to that observed. 

Shaker tube reactors are commonly used for the evaluation of catalysts at elevated pressure. The liquid reactant and powdered catalyst are introduced into a metal or glass ampoule, which is sealed and pressurized to a predetermined level with the gaseous reactant. The ampoule is immersed into a thermostatted liquid and maintained at this temperature for a certain period of time while shaking. Then the reactor is opened and the reaction mixture analysed. Ampoules of ca. 10-100 cm are typically used. The usefulness of data obtained using such reactors for process scale-up is nearly zero due to poor agitation and unknown hydrodynamics in the ampoule. These reactors are, however, very useful for fast screening of catalysts. 

---