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.     

Enantioseparation of a chiral epoxide by simulated moving bed chromatography using Chiralcel-OD

Summary The feasibility of using simulated moving bed (SMB) chromatography for the chiral separation of a racemic epoxide with Chiralcel-OD as the stationary phase is demonstrated on a semi-preparative scale. Operating conditions for the separation are chosen with the help of a simple chart that depicts visually the interrelationships between the system flow rates and the SMB design criteria. The 12 column (each 100 mm×16 mm ID) SMB system continuously resolved the racemic mixture at a rate of 11.5 g/24 hr into streams with 95% and 94.4% e.e. (enantiomeric excess). A comparison of the SMB process with an optimized multiple-injection conventional chromatographic separation showed similar specific production rates for both methods, but a seven-fold lower solvent consumption for the SMB.     

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.     

Resolution of a racemic pharmaceutical intermediate. A comparison of preparative HPLC, steady state recycling, and simulated moving bed

Preparative HPLC and simulated moving bed (SMB) chromatography were used to resolve significant quantities of a racemic pharmaceutical intermediate. In addition, smaller scale studies using closed-loop recycling and steady state recycling (SSR) were performed so that a meaningful comparison of all these techniques could be made using the same real world separation. A highly optimized, six-column SMB process was clearly the superior technique and was used for the process-scale (247 kg of racemate) resolution. At the more moderate lab-scale (33 kg of racemate and 19 kg of racemate), a frequently used but less optimized eight-column SMB process was used. It was found that SSR was comparable to the lab-scale SMB process in productivity and solvent consumption. Thus, it appears that SSR can be a useful choice at such moderate scales. Finally, at moderate scales when neither SSR nor SMB is available, it was found that acceptable results were obtained with both closed-loop recycling and with a two-step preparative process.     

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.     

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.     

Chiral separation and modeling of the three-chiral-center beta-blocker drug nadolol by simulated moving bed chromatography

Nadolol, a beta-blocker used in the management of hypertension and angina pectoris, has three chiral centers and is currently marketed as an equal mixture of its four stereoisomers. Resolution of three of the four stereoisomers of nadolol was obtained previously by HPLC, with a complete separation of the most active enantiomer (RSR)-nadolol, on a column packed with perphenyl carbamoylated beta-cyclodextrin (beta-CD) immobilized onto silica gel. In this study, continuous separation of the target enantiomer of (RSR)-nadolol from its racemic mixture (which is a ternary mixture in the chromatographic system) was studied by non-linear SMB chromatography. Different regions of (2, 3) and (1, 2) complete separation regime were determined in the (m2, m3) region and the effect of non-linearity such as overall feed concentration and component composition on the separation performances was investigated. A direct simulation approach has been proposed to simulate the SMB separation performance for the pseudo-binary mixture of nadolol. The simulation was conducted on the basis of a shortcut method constituted only of the weak-key and strong-key components. The performance of the cyclic steady-state behavior of the SMB unit was predicted reasonably well. It was also discussed quantitatively that the complete separation region obtained from the shortcut method is a subset of the true complete separation region and the optimal separation conditions obtained differed slightly from the "true" separation.     

Intermittent simulated moving bed chromatography: 1. Design criteria and cyclic steady-state

The intermittent SMB (I-SMB) process is a multi-column chromatographic process, which is a modification of the conventional SMB process, has been applied so far only in the sugar industry and is claimed to achieve higher productivity. In the I-SMB process the time interval between two port switches is divided in two sub-intervals, and only during the first the product streams are collected. The potential of the I-SMB technology is demonstrated in the case of the separation of a binary mixture subject to the linear isotherm by using both the equilibrium theory of chromatography and detailed simulations. It is shown that a I-SMB with only four columns can achieve much higher separation performance than a SMB unit with four columns.     

Simulated moving bed technology with a simplified approach for protein purification. Separation of lactoperoxidase and lactoferrin from whey protein concentrate

Simulated moving bed (SMB) technology is a continuous chromatographic technique proven to have many advantages compared to conventional batch chromatography, such as: raised productivity and product concentration, reduced buffer consumption as well as more efficient use of raw material. In this study a 20 column SMB process for the separation of lactoperoxidase and lactoferrin from whey protein concentrate (WPC) was developed. A simplified approach with data from a single column experiment was used when designing the process. The SMB process data were compared to a theoretical scale-up of the breakthrough experiment reflecting the same 20 column set-up run in non-moving bed mode. The outcome of the comparison is a 48% raise in productivity, a 4.3 times decrease in buffer consumption, 6.5 times raise in target protein concentration with a raw material utilization which is slightly better for the SMB process.     

Chromatographic resolution of the enantiomers of a pharmaceutical intermediate from the milligram to the kilogram scale.

The preparative chromatographic resolution of racemic mixtures is rapidly becoming a standard approach for the generation of enantiomers in pharmaceutical R&D. This paper will discuss the optical resolution of a pharmaceutical intermediate as the separation is scaled up from the milligram to the kilogram scale. Difficulties encountered and their solutions at each scale will be discussed. In addition, the exploration of Simulated Moving Bed (SMB) for the separation will also be discussed. Finally, a comparison of the productivities and solvent consumption for each method and scale will be presented.     

Discontinuous and continuous separation of the monomeric and dimeric forms of human bone morphogenetic protein-2 from renaturation batches

Bone morphogenetic protein-2 (BMP-2) is one of the most interesting of the approximately 14 BMPs which belong to the transforming-growth-factor-beta (TGF-beta) superfamily. BMP-2 induces bone formation and thus plays an important role as a pharmaceutical protein. Recently, rhBMP-2 has been produced in form of inactive inclusion bodies in Escherichia coli. After solubilization and renaturation the biologically active dimeric form of rhBMP-2 can be generated. However, inactive monomers of BMP-2 are also formed during the renaturation process which must be separated from the active dimeric BMP-2. The purpose of this paper is to present: (a) results of an experimental study of a chromatographic separation of the monomeric and dimeric forms; and (b) a concept for a continuous counter-current simulated moving bed (SMB) process. The capacity of heparin as stationary phase was estimated for different salt concentrations in the mobile phase. A simulation study of a three-zone SMB process was performed applying a two step salt gradient. The results reveal the potential of the process for the purification of the dimeric BMP-2.     

Effect of the homogeneity of the column set on the performance of a simulated moving bed unit. II. Experimental study

Previous studies of the simulated moving bed (SMB) process assume identical characteristics of all the columns incorporated in a given unit. Due to the practical impossibility to manufacture identical columns, numerical applications of the theory to modeling and optimization use for each of the needed column parameter the average value for the entire column set. In this study, the effects of these simplifications on the actual productivity of the SMB process are evaluated by making exact calculations, i.e., by taking the differences in the porosity values into account. We apply a revised set of separation conditions previously introduced and derived from the equilibrium theory. Earlier theoretical results are compared to experimental results obtained in the study of the enantiomeric separation of Tr?ger's base on Chiralpak AD. Due to the nonLangmuirian character of the adsorption isotherms of these two compounds on the packing material used, the separation area cannot be determined analytically. As an alternative, a reliable numerical algorithm was used to scan a wider region and to define the separation area. The form of this area depends on the applied porosity values. A UV detector and a laser polarimeter located at one node of the SMB monitor on-line the internal concentration profiles. Excellent agreement between the calculated and the experimentally determined concentration profiles was obtained under nonlinear conditions. The influence of column-to-column variations on the performance of the SMB process was found to be more significant under nonlinear than under linear conditions.     

Separation of stereoisomers in a simulated moving bed-supercritical fluid chromatography plant

The combination of two techniques, simulated moving bed (SMB) and supercritical fluid chromatography (SFC), leads to an apparatus with unique features. Besides the known advantages of the SMB process, like reduced solvent consumption and its continuity, the use of supercritical carbon dioxide as the mobile phase offers an easy product recovery by depressurizing the supercritical fluid. Details of a SMB-SFC plant are presented for the first time. Due to the large number of process parameters a simulation of the SMB process is necessary to achieve optimal operating conditions. The most important thermodynamic information for a SMB process is the adsorption isotherms. Therefore, isotherms for two phytol isomers are measured and correlated. A fast dynamic model for the simulation of SMB is used to calculate the region of complete separation taking different column configurations and the compressibility of the mobile phase into account.     

Experimental implementation of identification-based optimizing control of a simulated moving bed process

Experimental implementation of an optimizing controller based on identified model for the separation of nucleosides in a laboratory scale simulated moving bed (SMB) unit is reported in this study. The manipulative variables are the three external and one internal flow rates while the outputs are productivity, solvent consumption, and purities of extract and raffinate streams averaged over a switching period. The feedback information is the concentration profile of extract and raffinate measured online using two ultraviolet (UV) detectors. Experimental results show that the designed controller is able to operate the SMB units under optimal condition fulfilling the purity requirements. Besides, the controller demonstrated excellent performance in terms of rejecting disturbances that may occur during SMB operations.     

Variable desorbent strength: influence on SMB operating conditions and performance

The aim of this work was to evaluate the role of desorbent selectivity variation on the tuning and the performance of a SMB process. For this purpose a separation regions study in the case of a four-zones non-linear transfer limited SMB was carried out. The SMB unit was modelled considering the equivalent True Moving Bed (TMB). A set of 11 desorbents with different strength was considered: 3 desorbents with constant strength and 8 desorbents with variable strength. For each system, the optimal operating conditions are determined using the separation regions approach, with plots in both (Q₂, Q_F) and (Q₄, Q_D) planes. Depending on the separation considered, a variable selectivity desorbent can lead to an improvement or can be detrimental to process performances. A careful choice of desorbent selectivity (either constant or variable) is then crucial to achieve maximal process performance.     

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.     

Effect of the homogeneity of the column set on the performance of a simulated moving bed unit. I. Theory

Although it is impossible to manufacture identical columns for use in a simulated moving bed (SMB) process, theoretical studies assume that all the columns in an SMB unit have identical characteristics. In practice, calculations in modeling and optimization studies are made with the average values of each column parameter set. In this report, the effects on SMB process performance caused by column-to-column fluctuations of the parameters are discussed. As a first step, we show how the differences in porosity of the columns may be taken into account with a revised set of separation conditions. Reductions in the purity of the extract and the raffinate streams are quantitatively related to the column-to-column fluctuations of the retention times of the two components arising from these porosity differences. For the sake of simplicity, the discussion first addresses the case of a four-column SMB operating under linear conditions. Then, the scope is extended to the cases of SMB units incorporating several columns in each section and to SMB units operating under nonlinear conditions.     

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.     

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.     

Optimization of simulated moving bed chromatography with fractionation and feedback: Part II. Fractionation of both outlets

A new improvement based on outlet fractionation and feedback has been developed for simulated moving bed (SMB) chromatography. In this contribution, this fractionation and feedback SMB (FF-SMB) concept is extended to the general scenario which integrates a simultaneous fractionation of both outlet streams. A model-based optimization approach, previously adopted to investigate single fractionation, is extended to consider this flexible fractionation policy. Quantitative optimization studies based on a specific separation problem reveal that the double fractionation is the most efficient operating scheme in terms of maximum feed throughput, while the two existing single fractionation modes discussed in our previous study are also significantly superior to the conventional SMB operation. The advantages of the double fractionation extension are further demonstrated in terms of several more detailed performance criteria. In order to evaluate the applicability of the fractionation and feedback modification, the effect of product purity, adsorption selectivity, column efficiency and column number on the relative potential of FF-SMB over SMB is examined.