Continuous Ultrafiltration Control for Variable Feed and Membrane Fouling
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Solution Overview
Problem
Conventional systems face challenges in continuously monitoring and controlling ultrafiltration processes, particularly in biopharma manufacturing, due to variability in feed concentration, membrane fouling, and complex scheduling requirements, which affect the concentration of monoclonal antibodies and other therapeutic agents.
Innovation Solution
A system and method utilizing sensors, data processing, and control strategies to optimize feed flowrate and pressure, incorporating a fouling index, for robust ultrafiltration operations, including data preprocessing, prediction, optimization, and fault detection to maintain target volumetric concentration factor (VCF) and throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional ultrafiltration processes are used to concentrate monoclonal antibodies, then product concentration is achieved, but feed concentration variability and membrane fouling cause inconsistent output and process complexity
Solution Approach 1:
The patent implements a feedback control system using Process Analytical Technology (PAT) tools including in-line sensors (refractive index, UV-Vis, fluorescence) to monitor feed concentration in real-time. The controller adjusts operating parameters (feed flowrate, transmembrane pressure) based on this feedback to maintain consistent retentate concentration output despite feed variability, thereby resolving the contradiction between manufacturing precision and process complexity
Solution Approach 2:
The system dynamically changes operating parameters (feed flowrate, transmembrane pressure, spool valve position) based on real-time feed concentration measurements. By continuously adjusting these parameters through automated control, the system maintains consistent product concentration without requiring complex manual intervention, addressing both precision and complexity concerns
2Productivity
If continuous ultrafiltration operation is implemented to handle varying feed concentration, then productivity is improved, but process control becomes tedious and complex
Solution Approach 1:
The patent implements an automated self-regulating control system where the controller automatically adjusts feed flowrate and transmembrane pressure based on real-time sensor data without operator intervention. The system monitors its own performance and makes necessary adjustments autonomously, enabling continuous operation while simplifying ease of operation by eliminating tedious manual control
Solution Approach 2:
The patent replaces manual mechanical control with an automated electronic control system using motors, spool valves, and computer-based controllers. This substitution enables continuous operation with consistent precision while dramatically improving ease of operation by removing the need for tedious manual adjustments
3Productivity
If membrane fouling occurs during ultrafiltration, then throughput is maintained initially, but concentration polarization and fouling reduce flux over time
Solution Approach 1:
The patent implements periodic backflushing cycles where the filtration direction is reversed at scheduled intervals to remove accumulated fouling from the membrane surface. This periodic cleaning action maintains consistent flux over extended operation periods by preventing irreversible fouling, thereby resolving the contradiction between initial throughput and long-term flux consistency
Solution Approach 2:
The system maintains continuous productive operation by implementing proactive fouling management through real-time monitoring and periodic backflushing. This approach ensures uninterrupted ultrafiltration operation with consistent flux by preventing fouling accumulation, addressing both productivity and reliability requirements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables continuous, efficient, and reliable ultrafiltration by dynamically adjusting operating conditions to handle real-time feed variations, reducing membrane fouling, and optimizing process parameters for consistent product concentration.
Implementation Method 1
Membrane ultrafiltration (UF) is a pressure-modified, convective process that uses semipermeable membranes to separate species in aqueous solutions by molecular size, shape, and/or charge
Implementation Method 2
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed
Data Source
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AI summary
This disclosure relates generally to method and system to monitor and control continuous ultrafiltration (UF) process units. In real time, continuous operation of UF to handle variating concentration in feed stream is tedious and complex. The UF plant system receives a plurality of input data configured to UF process units and from the real time data outliers are removed and missing values are imputed. The prediction module predicts a volumetric concentration factor (VCF) value and a throughput value by selecting a model from a model repository. The optimization module optimizes the VCF value, and the throughput value based on a plurality of optimal variables recommended for a given feed concentration. The UF plant system controls the VCF value and the throughput value for a predefined period of a prediction horizon based on a plurality of trajectory profiles recommended for the feed flow rate, the pressure data, and a feed concentration.