Effect of salt gradients on the separation of dilute mixtures of proteins by ion-exchange in simulated moving beds

Salt gradients can improve the efficiency during fractionation of proteins by ion-exchange in simulated moving beds (SMBs). The gradients are formed using feed and desorbent solutions of different salt concentrations. The thus introduced regions of high and low affinity may reduce eluent consumption and resin inventory compared to isocratic SMB systems. This paper describes a procedure for the selection of the flow-rate ratios that enables successful fractionation of a dilute binary mixture of proteins in a salt gradient. The procedure is based on the so-called "triangle theory" and can be used both for upward gradients (where salt is predominantly transported by the liquid) and downward gradients (where salt is predominantly transported by the sorbent). The procedure is verified by experiments.     

Solvent gradient operation of simulated moving beds. I. Linear isotherms

The simulated moving bed (SMB) is a multi-column chromatographic separation process, which--with respect to the single-column preparative batch process--allows for a continuous separation with larger productivity and smaller solvent consumption at the same time. The benefits of this process have been shown for several different applications in fine chemistry, particularly for the separation of enantiomers. In general, SMBs are operated under isocratic conditions. However, separation performance can be further improved by applying some sort of gradient mode operation, in order to optimize the operating conditions of each individual section of the unit. This can be achieved by tuning the retention behavior of the solutes to be separated along the unit, namely by enforcing weak adsorption conditions in sections 1 and 2, and strong adsorption conditions in sections 3 and 4. This can be achieved by applying a temperature gradient (high temperature in section 1, and low temperature in section 4), a pressure gradient (e.g. in the supercritical SMB, when pressure is high in section 1, and low in section 4), or a solvent gradient, which is the aim of this work. In the solvent gradient mode the mobile phase consists of a mixture of two or more solvents. To different mobile phase compositions corresponds a different retention behavior of the solutes, i.e. different adsorption isotherms. In this work we study a closed loop SMB unit with solvent mixtures of two different compositions entering the unit at the feed and desorbent inlet ports, respectively. Thereby two different mobile phase compositions are established in sections 1 and 2, and sections 3 and 4, respectively. To optimize this process the equilibrium theory design criteria for non-linear SMBs are extended to describe this operation mode. It is shown how the region of separation is derived and how the optimal operating conditions can be found. Finally the solvent gradient mode is compared with the isocratic mode in terms of productivity and solvent consumption.     

Effect of mobile phase composition on the SMB processes efficiency. Stochastic optimization of isocratic and gradient operation

The solvent composition was adjusted in a theoretical study in order to maximize the efficiency of a simulated moving bed (SMB) process. The isocratic realization of the process as well as the solvent gradient mode were considered. The solvent composition and the flow rates were used as decision variables in a random search optimization algorithm known to be a reliable tool for nonlinear programming problems. The results of the optimization indicate that the optimal composition of the mobile phase depends strongly on the feed concentration. The asymmetry of the internal concentration profiles, which has a negative effect on the separation efficiency, can be partly damped by an increase of the solvent strength. In the cases studied the optimal solvent strength determined for concentrated feed streams is higher than that for diluted ones. Moreover, the optimum is strongly influenced by the value of the selectivity factor and its dependency on the mobile phase composition. Different results were obtained for cases, in which the separation factor increases with increasing the modifier concentration, than for cases, in which the separation factor decreases with increasing the modifier concentration. A similar analysis was performed for a solvent gradient SMB process, in which different solvents are used at the two inlet ports: a weak solvent in the feed stream and a strong solvent in the desorbent stream. Again the optimal mobile phase composition was strongly affected by the type of the isotherms and their non-linearity. The potential of a gradient SMB process in terms of increasing the productivity and reducing the eluent consumption is exemplified.     

Two-step solvent gradients in simulated moving bed chromatography. Numerical study for linear equilibria

The application of gradients in simulated moving bed (SMB) chromatography has recently attracted interest as a method for further improving the performance of this continuous separation process. One possible implementation of gradients consists in setting the solvent strength in the desorbent stream higher than that in the feed stream. As a result, the components to be separated are more retained in the zones upstream of the feed position and more easily eluted in the zones downstream of the feed position. If a liquid mobile phase is used, gradients can be created by dosing different solvents into the feed and desorbent ports. In a closed-loop gradient SMB arrangement the solvent strength within the unit will depend on the two feed compositions and on the characteristic flow-rates of the process. In this work an equilibrium stage model describing a true moving bed process is used to analyze numerically the main features of a two-step gradient SMB process. The adsorption isotherms are assumed to be always linear under isocratic conditions. The relevant Henry constants depend in a nonlinear manner on the composition of the solvent. Based on numerical simulations the impact of the two inlet solvent compositions is demonstrated in terms of the size and shape of regions of applicable flow-rates. Different strategies of designing the process are discussed and compared with respect to maximizing productivities and minimizing desorbent requirements.     

Adsorption of monoclonal antibody variants on analytical cation-exchange resin

Monoclonal antibody (MAb) variants differing by one or two C-terminal lysine residues can be separated by cation-exchange chromatography due to the difference in their charge distribution. The adsorption of the three MAb variants on a weak cation-exchange resin was characterized using directly the raw mixture in spite of the presence of some impurities. The effects of both, pH and eluent salt concentration, on the adsorption isotherm were investigated. Under certain experimental conditions distorted peak shapes and even peak doubling for single variant injections were obtained, in addition to unexpectedly long retention times. These observations were explained based on equilibrium theory. The separation of the MAb variants was designed for an isocratic and a linear salt gradient operation. The corresponding optimal values of pH and salt concentration were determined. The use of salt gradients not only allows reducing the process time and increasing enrichment of the variants, but also leads to some loss in purity. A baseline separation could be obtained under isocratic and strongly adsorbing conditions at pH 6.3. A lumped kinetic model and a procedure for estimating the corresponding parameters were developed and validated by comparison with experimental elution chromatograms in a wide range of operating conditions.     

Solvent gradient operation of simulated moving beds. 2. Langmuir isotherms

Simulated Moving Bed separations of enantiomers or fine chemicals are usually carried out in the isocratic mode, i.e. by applying the same operating conditions (temperature, pressure, mobile phase composition, pH) in the whole SMB unit. However, it has been recently recognized that by properly modulating operating conditions in the SMB sections. i.e. Sections 1-4 normally, separation performance in terms of productivity and solvent consumption can be significantly improved. In this work, we study solvent gradient SMB (SG-SMB) operation, where the concentration of a modifier in the main solvent constituting the mobile phase is adjusted along the SMB unit, so as to have weaker retention of the species to be separated in the first two sections, and stronger retention in Sections 3 and 4. Overload chromatographic conditions are considered, where the adsorption behavior is characterized by a nonlinear competitive adsorption isotherm, e.g. a binary Langmuir isotherm. Design criteria to achieve complete separation are developed in the frame of the equilibrium theory of chromatography. The theoretical findings are discussed in view of typical effects of the modifier concentration on retention times and solubility of the species to be separated, and an overall assessment of the SG-SMB technology is attempted.     

Hydrophobic interaction chromatography of proteins. I. Comparison of selectivity

Currently, the selection of a hydrophobic interaction chromatography (HIC) sorbent for protein separation purposes is entirely based on empirical means. An attempt was made to characterize different HIC sorbents from various manufacturers. The selectivity was determined by isocratic pulse experiments of a set of reference proteins and an algorithm was developed to classify the sorbents according to their selectivity and hydrophobicity. The obtained semi-quantitative parameters take into account the dependence of salt on adsorption. The sorbent characteristics evaluated with the model proteins were compared to the separation of a real feedstock. A good agreement was achieved between the developed evaluation procedure and the separation behaviour of the real feed stock.     

Optimization of simulated moving bed plants with low efficient stationary phases: separation of fructose and glucose

An optimization procedure for simulated moving bed (SMB) plants with low efficient stationary phases is presented. The new aspect is that the desorbent consumption can be cut by 70% by running the plant with lower internal liquid flows and a corresponding larger switch time while the productivity is kept constant. This concept was validated by the separation of fructose and glucose in water on a calcium resin with an eight-column SMB plant. The separation can be predicted well by a true moving bed (TMB) and a simulated moving bed simulation. Adsorption isotherms were determined up to 300 kg/m3 for glucose and 500 kg/m3 for fructose from 25 to 80 degrees C. Experimental SMB runs were performed over a wide range of feed concentrations (10-350 kg/m3) and temperatures (25-80 degrees C). The strong influence of the delay volume is pointed out. For an experimental run with high feed concentration a complete set of data is presented. To reduce biological growth separation at 80 degrees C is recommended.     

Step gradients in 3-zone simulated moving bed chromatography. Application to the purification of antibodies and bone morphogenetic protein-2

The simulated moving bed (SMB) technology is a proven tool for efficient separation of binary mixtures. However, relying on isocratic conditions limits the applicability of the classical SMB approach when considering the field of bioseparations. Here, the use of gradients opens up new possibilities. A gradient in a SMB process can be established by using different solvent strengths in the incoming feed and desorbent streams, resulting in two internal plateaus of elution strength. Thus, compared to the conventional process, the overall amount of solvent needed can be reduced, productivity can be increased and more concentrated product streams can be obtained. In this contribution, two case studies will be presented. At first, the separation of bovine IgG from lysozyme will be analyzed as a model system. Antibodies are a common target substance in bio-chromatography, as therapeutic monoclonal antibodies are among the most promising biopharmaceuticals. Using adsorption data obtained from single-column experiments, an appropriate SMB process was designed and implemented. The second target component is the active dimeric form of the bone morphogenetic protein-2 (BMP-2). This protein was isolated from a renaturation solution, which also contained its inactive monomeric form as well as other undefined proteins from the bacterial production strain. A 3-zone open-loop gradient-SMB approach was used successfully for both separations.     

Generic approach to the method development of intact protein separations using hydrophobic interaction chromatography

We describe a liquid chromatography method development approach for the separation of intact proteins using hydrophobic interaction chromatography. First, protein retention was determined as function of the salt concentration by isocratic measurements and modeled using linear regression. The error between measured and predicted retention factors was studied while varying gradient time (between 15 and 120 min) and gradient starting conditions, and ranged between 2 and 15%. To reduce the time needed to develop optimized gradient methods for hydrophobic interaction chromatography separations, retention‐time estimations were also assessed based on two gradient scouting runs, resulting in significantly improved retention‐time predictions (average error < 2.5%) when varying gradient time. When starting the scouting gradient at lower salt concentrations (stronger eluent), retention time prediction became inaccurate in contrast to predictions based on isocratic runs. Application of three scouting runs and a nonlinear model, incorporating the effects of gradient duration and mobile‐phase composition at the start of the gradient, provides accurate results (improved fitting compared to the linear solvent‐strength model) with an average error of 1.0% and maximum deviation of –8.3%. Finally, gradient scouting runs and retention‐time modeling have been applied for the optimization of a critical‐pair protein isoform separation encountered in a biotechnological sample.     

Optimization of simulated moving bed and column chromatography for a plasmid DNA purification step and for a chiral separation

This work analyzes the performance of the SMB and the column chromatography processes for two different case studies: the first stage of the plasmid DNA (pDNA) polishing, and the Tr?ger's base enantiomer separation, in which the adsorption isotherms are linear and non-linear, respectively. Simulation tools are used together with an optimization routine (Non-Sorting Genetic Algorithm (NSGA)) in order to find the optimum operating conditions leading to maximum productivity and minimum solvent consumption; the optimum solution for each of the processes is a curve on the productivity-solvent consumption plane, the so-called Pareto set. The comparison between the column and the SMB processes is based on the relative position of the two Pareto sets calculated at equal conditions and for the same final purity and recovery of the target species. The results show that SMB is superior to column chromatography in the two case studies investigated, i.e. in the case of the linear isotherm (pDNA), the productivity gain is up to a factor two for a given value of the solvent consumption. Furthermore, the flexibility of the SMB operation is larger, since the Pareto sets are flatter and they prolong into regions of the productivity-solvent consumption plane that are not accessible with the column chromatography process.     

Novel simulated moving-bed method for reduced solvent consumption

Simulated moving-bed (SMB) chromatography is attractive for reducing sorbent and solvent consumption relative to fixed-bed systems. In this contribution, we describe a novel and versatile method for further reducing solvent consumption in the case of reversed-phase chromatography. The method is based on the variation of the distribution coefficients of solutes to be separated upon varying the composition of a multi-component mobile phase. If the solvent strength of the desorbent is set higher than the solvent strength of the feed, the components will have smaller distribution coefficients in the extraction section of the SMB and hence will be more easily eluted. This will result in a lower desorbent flow and possibly also in a shorter desorbent zone, and, ultimately, in more concentrated products. The so-called "Triangle-method" by Storti et al. [AIChE J., 39 (1993) 471] to obtain the region of complete separation, is extended for this novel SMB method. Theoretical evaluation of the proposed methodology supports the anticipated solvent reduction relative to fixed-bed RP-HPLC for the cases of the purification of the polyketide antibiotic nystatin and the separation of bovine insulin from porcine insulin.     

Micellar gradients in size-exclusion simulated moving bed chromatography

The selectivity of size-exclusion chromatography (SEC) can be modified by adding non-ionic micelles to the mobile phase. Surfactant-aided size-exclusion chromatography (SASEC) can therefore very well be performed in a gradient mode on an SMB, as is reported in this paper. A method has been developed for correctly positioning a micellar gradient over an SMB. The method is applied for size-exclusion chromatography with the non-ionic surfactant C12E23 as gradient forming solute, and demonstrated by applying it to a relevant chromatographic protein separation problem.     

Optimization of simulated moving bed chromatography with fractionation and feedback: Part I. Fractionation of one outlet

A novel modification of simulated moving bed (SMB) technology, referred to as fractionation and feedback SMB (FF-SMB), has been introduced recently. This concept is based on fractionating one or both outlet streams and feeding the off-spec fractions back into the unit alternatingly with the original feed mixture. In this paper, the optimization problem of FF-SMB realizing one outlet fractionation is considered. A mathematical optimization framework based on a detailed process model is presented which allows to evaluate quantitatively the potential of this operating scheme. Detailed optimization studies have been carried out for a difficult separation characterized by small selectivity and low column efficiency. The results reveal that the proposed fractionation and feedback regime can be significantly superior to the classical SMB chromatography, in terms of both feed throughput and desorbent consumption. The effect of the feeding sequence on the performance of FF-SMB is also examined.     

Streamlined,two-column,simulated countercurrent chromatography for binary separation

We report on a numerical and experimental study of two-column versions of streamlined, multicolumn, semi-continuous chromatography for binary separation. The systems combine a flexible node design, cyclic flow-rate modulation, and relayed operation of the inlet/outlet ports to extend the mass-transfer zone over the largest possible length, while keeping it inside the system at all times. One advantage of these streamlined designs is the simplicity of their physical realization: regardless of the number of columns, they only require two pumps to supply feed and desorbent into the system, while the flow rates of liquid withdrawn from the system are controlled by material balance using simple two-way valves. In one case, an extra pump is needed to recirculate the fluid in closed-loop. A rigorous model-based optimization approach is employed in the optimal design of the cycles to generate solutions that are physically realizable in the experimental set-ups. The optimized schemes for two-column operation supply fresh feed into the middle of the system where the composition of the circulating fluid is closest to that of the feedstock fluid, and recover the purified products, extract and raffinate, alternately at the downstream end of the unit, while desorbent is continuously supplied into the upstream end of the system. By internally recycling part of the non-pure cut fraction, the scheme with a step of closed-loop recycling significantly reduces its solvent consumption. The feasibility and effectiveness of the reported two-column processes have been verified experimentally on the linear separation of nucleosides by reversed phase subject to 99% purity constraints on both products. It is shown that our processes compare favorably against single-column batch chromatography, steady-state recycling, and four-column, open-loop SMB, for the same amount of adsorbent; they are also better than the four-column, closed-loop SMB at high feed throughputs.     

Simulated moving bed chromatography for the separation of enantiomers

Simulated moving bed (SMB) chromatography, a continuous multi-column chromatographic process, has become one of the preferred techniques for the separation of the enantiomers of a chiral compound. Several active pharmaceutical ingredients, including blockbuster drugs, are manufactured using the SMB technology. Compared to single column preparative chromatography, SMB separations achieve higher productivity and purity, while reducing the solvent consumption. The SMB technology has found applications both at small and large scales. Design methods have been developed for robust operation and scale-up, using data obtained from analytical experiments. In the last few years, rapid developments have been made in the areas of design, improved process schemes, optimization and robust control. This review addresses these developments, as well as both the fundamentals of the SMB science and technology and some practical issues concerning the operation of SMB units. Particular emphasis is placed on the consolidation of the “triangle theory”, a design tool that is used both in the academia and industry for the design of SMB processes.     

模拟移动床色谱技术及其应用

详细地介绍了一种现代化分离技术模拟移动床色谱技术的发展历史及其工作原理,同时介绍了模拟移动床色谱在石油化工、糖醇分离、手性化合物及其他方面的主要应用。     

模拟移动床色谱法拆分甲霜灵对映体

模拟移动床(SMB)色谱作为一种精确、高效的制备色谱技术引起研究者的极大关注。本文以EnantioPak OD填料为手性固定相,正己烷-乙醇(70 : 30, v/v)为流动相,在四区模拟移动床上手性拆分甲霜灵外消旋体。采用旋光检测器研究甲霜灵异构体在手性柱上的洗脱顺序;探讨进样浓度、进样流速、各区流速和切换时间等条件对手性分离甲霜灵外消旋体的影响,并与制备色谱进行比较。结果表明:S-(+)-甲霜灵先于R-(-)-甲霜灵被流动相洗脱,R-(-)-甲霜灵在色谱柱上的保留强于S-(+)-甲霜灵;在线性和非线性条件下,模拟移动床都能很好地拆分甲霜灵外消旋体,在优化SMB工艺条件下,S-(+)-甲霜灵和R-(-)-甲霜灵的光学纯度都大于99%;在样品质量浓度为15 mg/mL的条件下,模拟移动床色谱分离的样品量显著高于制备色谱,而流动相消耗仅为后者的1/9。这对于发展大规模色谱拆分甲霜灵工艺具有良好的指导意义。     

Simulated moving bed process with cyclic modulation of the feed concentration

The improvement of the simulated moving bed (SMB) process based on the introduction of a cyclic modulation of the feed concentration is described. It is demonstrated that such a feed concentration gradient during the shifting cycle can improve the performance significantly. The productivity and the product concentrations can be increased while simultaneously the solvent consumption can be decreased compared to the conventional SMB process with constant feed parameters.     

Implementation of an automated on-line high-performance liquid chromatography monitoring system for ‘cycle to cycle’ control of simulated moving beds

In continuous chromatography simulated moving bed (SMB) is a firmly established powerful technique for the separation of fine chemicals and enantiomers. The use of a controller could improve the operation conditions and increase the productivity of an SMB unit. However, the performance of any controller is greatly affected by the reliability and the quality of the feedback information from the plant. Therefore, to overcome the limitations of optical detectors, such as UV and polarimeter, an automated on-line HPLC monitoring system was developed and installed to monitor the product streams. The performance of the system is tested experimentally separating a mixture of guaifenesin enantiomers on Chiralcel OD columns with ethanol as mobile phase in our laboratory SMB unit under both linear and nonlinear chromatographic conditions. The results show that the new monitoring system provides precise and accurate data about the concentration of the components in the two product streams. Moreover, they prove that despite disturbances a combination of the controller and the new on-line monitoring system allows to fulfill the product specifications and to improve the performance of the process in terms of feed throughput and solvent consumption.