Process-scale Separations

Therefore, the locus of the values ( ) with a vanishing second derivative of A delimits the region of the miscibility gap in which spinodal decomposition occurs. This locus is referred to as the spinodal (figure C2.1.10 (bl). The length scale of the concentration fluctuations at the beginning of the separation process is controlled by... 

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). 

In contrast to trace impurity removal, the use of adsorption for bulk separation in the liquid phase on a commercial scale is a relatively recent development. The first commercial operation occurred in 1964 with the advent of the UOP Molex process for recovery of high purity / -paraffins (6—8). Since that time, bulk adsorptive separation of liquids has been used to solve a broad range of problems, including individual isomer separations and class separations. The commercial availability of synthetic molecular sieves and ion-exchange resins and the development of novel process concepts have been the two significant factors in the success of these processes. This article is devoted mainly to the theory and operation of these Hquid-phase bulk adsorptive separation processes. 

Dense Symmetrical Membranes. These membranes are used on a large scale ia packagiag appHcations (see Eilms and sheeting Packaging materials). They are also used widely ia the laboratory to characterize membrane separation properties. However, it is difficult to make mechanically strong and defect-free symmetrical membranes thinner than 20 p.m, so the flux is low, and these membranes are rarely used in separation processes. Eor laboratory work, the membranes are prepared by solution casting or by melt pressing. 

Reverse Osmosis. This was the first membrane-based separation process to be commercialized on a significant scale. The breakthrough discovery that made reverse osmosis (qv) possible was the development of the Loeb-Sourirajan asymmetric cellulose acetate membrane. This membrane made desalination by reverse osmosis practical within a few years commercial plants were installed. The total worldwide market for reverse osmosis membrane modules is about 200 million /yr, spHt approximately between 25% hoUow-ftber and 75% spiral-wound modules. The general trend of the industry is toward spiral-wound modules for this appHcation, and the market share of the hoUow-ftber products is gradually falling (72). 

A development in the 1960s was that of on-line elemental analysis of slurries using x-ray fluorescence. These have become the industry standard. Both in-stream probes and centralized analyzers are available. The latter is used in large-scale operations. The success of the analyzer depends on how representative the sample is and how accurate the caUbration standards are. Neutron activation analyzers are also available (45,51). These are especially suitable for light element analysis. On-stream analyzers are used extensively in base metal flotation plants as well as in coal plants for ash analysis. Although elemental analysis provides important data, it does not provide information on mineral composition which is most cmcial for all separation processes. Devices that can give mineral composition are under development. 

The clay-cataly2ed iatermolecular condensation of oleic and/or linoleic acid mixtures on a commercial scale produces approximately a 60 40 mixture of dimer acids and higher polycarboxyUc acids) and monomer acids (C g isomerized fatty acids). The polycarboxyUc acid and monomer fractions are usually separated by wiped-film evaporation. The monomer fraction, after hydrogenation, can be fed to a solvent separative process that produces commercial isostearic acid, a complex mixture of saturated fatty acids that is Hquid at 10°C. Dimer acids can be further separated, also by wiped-film evaporation, iato distilled dimer acids and trimer acids. A review of dimerization gives a comprehensive discussion of the subject (10). 

This section describes the use of separation processes which utilize membranes. Placement in this chapter is in recognition of the recent ascendency of industrial-scale rnernbrane-based separations, but it also reflects the iew that within a decade, many of these separation processes will be mainstream unit operations. Some approach that status already. Figure 22-46 shows the relath e size of things important in membrane separations. 

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. 

The phase separation process at late times t is usually governed by a law of the type R t) oc f, where R t) is the characteristic domain size at time t, and n an exponent which depends on the universality class of the model and on the conservation laws in the dynamics. At the presence of amphiphiles, however, the situation is somewhat complicated by the fact that the amphiphiles aggregate at the interfaces and reduce the interfacial tension during the coarsening process, i.e., the interfacial tension depends on the time. This leads to a pronounced slowing down at late times. In order to quantify this effect, Laradji et al. [217,222] have proposed the scaling ansatz... 

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). 

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. 

Although the outline of a chemical separation process could be obtained by tracer-scale investigations, the process could not be defined with certainty until study of it was possible at the actual separation plants. Therefore, the question in the summer of 1942, was as follows How could any separations process be tested at the concentration of plutonium that would exist several years later in the production plants when, at this time, there was not even a microgram of plutonium available This problem was solved through an unprecedented series of experiments encompassing two major objectives. First, it was decided to attempt the production... 

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