Biosep Unit 1

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INTRO TO BIOSEPARATION

ENGINEERING

Sem 2 2011/2012 ERT 313 BIOSEPARATION ENGINEERING


BIOLOGICAL PRODUCTS
Biological products - chemical classification
Solvents, e.g. ethanol, acetone, butanol
Cells, e.g. bakers yeast, brewers yeast, freeze dried lactobacillus
Crude cellular extracts, e.g. yeast extract, soy extracts
Organics acids, e.g. citric acid, lactic acid, butyric acid
Vitamins, e.g. ascorbic acid, vitamin B12
Amino acids e.g. lysine, phenylalanine, glycine
Gums and polymers, e.g. xanthan, gellan, dextran
Antibiotics, e.g. penicillins, rifanpicin, streptomycin
Proteins, e.g. industrial enzymes, egg proteins, milk proteins, whey protein
therapeutic enzymes, monoclonal antibodies, plasma proteins
Sugars and carbohydrates, e.g. glucose, fructose, starch, dextran
Lipids, e.g. glycerol, fatty acids, steroids
Nucleic acids, e.g. plasmids, therapeutic DNA
BIOLOGICAL PRODUCTS (with
different classification)

Biological products - chemical classification


Solvents, e.g. ethanol, acetone, butanol
Cells, e.g. bakers yeast, brewers yeast, freeze dried lactobacillus
Crude cellular extracts, e.g. yeast extract, soy extracts
Organics acids, e.g. citric acid, lactic acid, butyric acid
Vitamins, e.g. ascorbic acid, vitamin B12
Amino acids e.g. lysine, phenylalanine, glycine
Gums and polymers, e.g. xanthan, gellan, dextran
Antibiotics, e.g. penicillins, rifanpicin, streptomycin
Proteins, e.g. industrial enzymes, egg proteins, milk proteins, whey protein
therapeutic enzymes, monoclonal antibodies, plasma proteins
Sugars and carbohydrates, e.g. glucose, fructose, starch, dextran
Lipids, e.g. glycerol, fatty acids, steroids
Nucleic acids, e.g. plasmids, therapeutic DNA
Biological products - applications
Industrial chemicals, e.g. solvents, organic acids, industrial enzymes
Agrochemicals, e.g. biofertilizers, biopesticides
Pharmaceuticals, e.g. antibiotics, hormones, monoclonal antibodies,
plasma proteins, vaccines
Food and food additives, e.g. whey proteins, milk proteins, egg proteins,
soy proteins
Nutraceuticals, e.g. vitamins, amino acids, purified whey proteins
Diagnostic products, e.g. glucose oxidase, peroxidase
Commodity chemicals, e.g. detergent enzymes, insecticides
Laboratory reagents, e.g. bovine serum albumin, ovalbumin, lysozyme
Cosmetic products, e.g. plant extracts, animal tissue extracts
BIOLOGICAL PROD UCTS (with different
bioseparation process)
Product Nature of bioseparation required
Alcoholic beverages: Clarification, distillation
Beer, wine, spirits
Organic acids: Precipitation, filtration,
Acetic acid, citric acid adsorption, solvent
extraction
Vitamins: Precipitation, filtration,
Vitamin C, vitamin B12, adsorption, solvent
extraction
riboflavin
Amino acids: Precipitation, filtration,
Lysine, glycine, adsorption, solvent
extraction
phenylalanine
Antibiotics: Precipitation, filtration,
Penicillins, neomycin, adsorption, solvent
extraction
bacitracin
Carbohydrates: Precipitation, filtration,
Proteins: Filtration, precipitation,
centrifugation, adsorption,
Food and food additives
chromatography, membrane
Nutraceuticals based separations
Industrial enzymes
Hormones
Pharmaceutical
enzymes Plasma
derived products
Monoclonal antibodies
Growth factors
Clotting factors
Thrombolytics
r-DNA derived proteins
Diagnostic proteins
Vaccines
DNA based products: Filtration, precipitation,
centrifugation, adsorption,
DNA probes, plasmids,
chromatography, membrane
nucleotides, oligonucleotides based separations
Bioseparations engineering
◻ Definition: Recovery, isolation,
purification
and polishing of products
synthesized by biotechnological
processes

◻ Extended definition: Final


polishing steps of processes such as
Bioproduct/
Upstream Downstrea s
biotechnology
processin based
Bioreaction effluent
m treatment
Impuritie
g processing
and water purification s
Why do we need bioseparation?
◻ Enrichment of target product
◻ Reduction in bulk
◻ Removal of specific impurities
◻ Enhancement of product stability
◻ Achievement of product
specifications
◻ Prevention of product degradation
◻ Prevention of catalysis other than the
type desired
◻ Prevention of catalyst poisoning
Challenges in Bioseparations Engineering

•Low product concentration


•Large number of impurities,
•Thermolabile bioproducts.
•Narrow operating pH and ionic strength window
•Shear sensitivity of bioproducts
•Low solubility of bioproducts in organic solvents
•Instability of bioproducts in organic solvents
•Stringent quality requirements
•Percentage purity
•Absence of specific impurities

An ideal bioseparation process should combine high


throughput
with high selectivity, and should ensure stability of product.
A Good Bioseparation Process:

◻ Ensures desired purity of


product
◻ Ensures stability of
product
◻ Keeps cost low
◻ Is reproducible
◻ Is scalable
◻ Meets regulatory guidelines
Economic Importance of Bioseparation
Engineering

The purification of biological product


from their respective starting
material. Eg: cell culture media
: technically difficult and expensive

The critical limiting factor in the


commercialization of biological
product

Many cases, bioseparation cost


can be a substantial
component of the total cost of
bioprocessing
Economic importance of bioseparation
engineering (cost of bioseparation)
Product Bioseparation
cost (%)
Solvents e.g. ethanol, acetone 15-20
Cells, e.g. bakers yeast, brewers yeast 20-25
Crude cellular extracts, e.g. yeast extract 20-25
Organics acids, e.g. citric acid, lactic acid 30-40
Vitamins and amino acids e.g. lysine, ascorbic acid 30-40
Gums and polymers, e.g. xanthan, gellan 40-50
Antibiotics, e.g. penicillins, rifanpicin 20-60
Industrial enzymes, e.g. Amyloglucosidase, glucose isomerase 40-65
Non-recombinant therapeutic proteins, e.g. pancreatin, papain 50-70
r-DNA products, e.g. recombinant insulin, recombinant streptokinase 60-80
Monoclonal antibodies 50-70
Nucleic acid based products 60-80
Plasma proteins, human albumin, human immunoglobulins 70-80
ERT 313/4 BIOSEPARATION
ENGINEERING
Strategies for Bioseparation
A large number of bioseparation methods are available

The strategy is based on how best these can be utilized


for a given separation

The following need to be taken into account:


◻ The volume of process stream
◻ The relative abundance of the product in this
process stream
◻ The intended use of the product, i.e. purity
requirements
◻ The cost of the product
Conventional strategy:
The RIPP scheme
◻ Recovery, isolation, purification and polishing
◻ Based on a logical arrangement of bioseparation
methods
◻ Low-resolution (less selectivity), high-throughput (product)
techniques (e.g. precipitation, filtration, centrifugation,
crystallization) are first used for recovery and
isolation
◻ High-resolution techniques (e.g. adsorption,
chromatography, electrophoresis) are then used
for purification and polishing
The RIPP Scheme

• Multi-technique separation

• Process design should take into consideration


the following:
• The nature of starting material
• The initial location of the target product
• The volume of process stream
• The relative abundance of the product in the
starting
material
• The susceptibility to degradation of the product
• The desired physical form of the final product
• The quality requirements
• Costing
Commonly Used Bioseparation Processes
Low resolution-high throughput
◻ Cell disruption
◻ Precipitation
◻ Centrifugation
◻ Liquid-liquid extraction C2L2 PFSMD
◻ Leaching
◻ Filtration
◻ Supercritical fluid extraction
◻ Microfiltration
◻ Dialysis

High resolution-low High resolution-high


throughput throughput
◻ Ultracentrifugation •Ultrafiltration
◻ Adsorption •Fluidized bed
chromatography
◻ Packed bed
•Membrane
chromatography chromatography
◻ Affinity separation
◻ Electrophoresis
Objective & Typical Unit
Operations of The 4 Stages in
Stage
Bioseparation
Objectives Typical unit
operation
Recovery Remove/ collect cells, cells debris /other Filtration,
(separation of particulate. sedimentation,
insoluble) Reduce volume extraction,
adsorption
Isolation Remove material have properties widely Extraction,
of product different from those desired in adsorption,
product. Reduce volume ultrafiltratio
n,
precipitation
Purification Remove remaining impurities which Chromatography
,
typically similar to desired product in affinity method,
chemical functionality & physical functional
properties. precipitation
Polishing Remove liquid. Drying,
Convert product to crystallized form crystallizatio
n
Nature of Bioseparation
• Largely based on chemical separation
techniques
• Chemical separation techniques are modified
based on specific requirements
• Novel separations may be necessary in some
cases
• High throughput/productivity
• High selectivity
• Need to satisfy stringent quality requirements
• Need to take into account degradable material
• Low temperature operations
• Multi-technique separation
Basis of Separation
Biological products are separated based on one or several of the
following in combination:
• Size, e.g. filtration, membrane separation, gel- filtration,
centrifugation
• Density, e.g. centrifugation, sedimentation, flotation
• Diffusivity, e.g. membrane separation, supercritical fluid
extraction
• Shape, e.g. centrifugation, filtration, sedimentation
• Polarity, e.g. extraction, chromatography, adsorption
• Solubility, e.g. extraction, membrane separation,
precipitation, crystallization
• Electrostatic charge, e.g. adsorption, membrane separation
• Mobility, e.g. electrophoresis, membrane separation
• Volatility e.g. distillation, membrane distillation,
pervaporation
HOW TO CHOOSE
SEPARATION METHOD
1. What is the product?
2. What is the value of product?
3. What is the acceptable product quality for the
proposed end use?
4. Where is the product in the complex mixture?
5. What are the physical and chemical properties
of the product and the impurities?
6. Is the product stable?
7. What are the economic of the various isolation
procedure?
8. Are they any contamination / health risk?
9. Can the isolation procedure be scaled up?
Current Paradigm in The
Bioseparation
Replacement of the conventional RIPP scheme
by using new techniques which can
significantly cut down the number of steps needed
to bioseparation

Some of these new and emerging techniques


are:
• Membrane chromatography
• Expanded-bed chromatography
• High-resolution ultrafiltration
15BT403- Bioseparation
Technology
UNIT-I
Syllabus

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 Role and importance of Bioseparation in Biotechnology
General Theory about bio separation(Refer any Text books–Harrison, Belter, Krishna Prasad, and
Biotol Series)
Different sectors in Biotechnology (Biotol series)
Recovery in Modern and Classical Biotechnology (Biotol Series)
 Worked out Problem: Calculation of yield in Classical Biotechnology. (Biotol Series)
Stages in the recovery of Biomolecules (Biotol Series)
Separation range of unit operations based on primary separation factor.(Biotol Series)
RIPP Scheme(Refer Raja Gosh: Page No 9-10)
Problems and Requirement of bio product Purification
Properties of Biomolecules.(Refer Any book Harrison, Belter, Krishna Prasad, and Biotol Series)
Characteristics of Fermentation Broth..(Refer Any book Harrison, Belter, Krishna Prasad, and
Biotol Series)
Biological Activity (Refer Harrison)
Analysis of Purity (Refer Harrison Basic Principles of Engineering analysis- refer Harrison Page: 34-
39,(Simply discuss the purity and its importance from Harrison: From page 49…. Not in detail)
 Process Economics
Economics (Refer Krishna Prasad: Page 25-29)
Cost Cutting Strategies (Refer Krishna Prasad: Page: 33-37)
 Cell Disruption methods

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Introduction to Bioseparation
• The pharmaceutical, agrichemical, and biotechnology bioproduct
industries account for several billion dollars in annual sales.
• commodity foods and beverages. “bioproduct” that must be
extracted and purified

• Owing to intense competition, cost, price, and value are very closely
related, except in the case of completely new products that are
thoroughly protected by patents, difficult to copy, and of added
value to the end user.
• Products with these characteristics—“biotechnology products”—
have typically been developed at considerable cost (over $100
million for R&D alone in the case of recombinant therapeutic
proteins requiring clinical trials) and marketed at prices that allow
for the recovery of the development, production, and marketing
costs. Their total contribution to the bioproduct market is also in
the billions of dollars

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Cost of bioseparation

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Introduction to Bioseparation
• Bioseparation is largely based on chemical separation
processes
• Well established separation techniques is used in the
process industry.
• Differences between synthetic chemicals and biological
substances need to be kept in mind
• Low molecular weight compounds such as vitamins
and amino acids are purified using conventional
separation techniques such as liquid-liquid extraction,
packed bed adsorption, evaporation and drying with
practically no modifications being necessary
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• Modified separation techniques are required for
purifying more complex molecules such as
proteins, lipids, carbohydrates and nucleic acids.
• The attributes of bioseparation which distinguish
it from chemical separation are:
 Monoclonal antibodies are typically
present in concentrations around 0.1 mg/ml
in the mammalian cell culture supernatants

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 Impurities and in some instances
byproducts are present in the starting
material along with target biological products
Sringent quality requirements for products
used for prophylactic, diagnostic and
therapeutic purposes both in terms of active
product content as well as in terms of the
absence of specific impurities.

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 Biological products are susceptible to
denaturation and other forms of degradation.
Extremes of physicochemical conditions such
as pH and ionic strengths, hydrodynamic
conditions such as high shear rates, and
exposure to gas-liquid interfaces.
 Many biological products are thermolabile

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Biological products classified based on
chemical nature

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Biological products classified based on
application

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Physical forms separated in
bioseparation
• Particle-liquid separation
• Particle-particle separation in liquid medium
• Particle-solute separation in liquid medium
• Solute-solvent separation
• Solute-solute separation in liquid medium
• Liquid-liquid separation

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Bioseparation techniques

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• Different sectors of Products
– Three Market sectors
• I- Therapeutic protein sector
• II- Diagnostic and Monoclonal Antibodies
• III – Industrial Bulk products

• Ref- Biotol series (page 3)

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Leading Biotechnology Proteins

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Primary separation factors of Biomolecules

Ref Biotol series(Page No 10)

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The RIPP scheme

• While developing a bio separation process the following should be taken


into consideration:
• 1. The nature of starting material: e.g. a cell suspension, a crudeprotein
solution
• 2. The initial location of the target product: e.g. intracellular,extracellular,
embedded in solid material such as inclusionbodies
• 3. The volume or flow-rate of the starting material
• 4. The relative abundance of the product in the starting material,i.e. its
concentration relative to impurities
• 5. The susceptibility to degradation e.g. its pH stability, sensitivityto high
shear rates or exposure to organic solvents
• 6. The desired physical form of the final product, e.g. lyophilizedpowder,
sterile solution, suspension
• 7. The quality requirements, e.g. percentage purity, absence ofendotoxins
or aggregates
• 8. Process costing and economics

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RIPP

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Downstream Process Economics
• Strategies for initiation of project
- Estimation of Capital and Operating cost
• Process Design Criteria
• Design Exercise
– Process Yield and Operating Parameter
– Calculation of process detail
( Refer Ram Prasad Page 24 -31)

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Cost Cutting Strategies
Analyze the technology or cost
– Identify inefficiencies and expenses
– Process involves review of organizational
structures,business requirements,existing
infrastructures, growth trends, growth
factors,resourses,expenses,and strategies.
– Organizational structures
– Analyse all fixed and variable cost

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Cost cutting strategies can be adopted
– Initiation of the new project
– Upgradation of existing project
– Existing loss making facilities
Three important factors in Cost cutting strategies
Design and economic analysis
early stage of development
Analysis of goods (COG)
Identify cost drives
Comparison of bioprocess alternatives
Facility design , engineering and Construction

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Cost Cutting strategies and
Implementation
• Capital cost reduction
• Design a down stream process to produce
marketable products
• Cost of downstream processing
• Isolation of microorganism of potential
industrial interest
• Strain Improvement

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Cost Cutting strategies and
Implementation
• Reduction of capital cost

• Reduction of the cost of production media


• Convert classical batch process to effective
continuous process
• Reduce overhead cost by proper process and
product design
• Process line utensild, materials, and resourse
standardization

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Cost Cutting strategies and
Implementation
• Strategies to design quality policies
• Cost cutting drives

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PRIMARY SEPARATION
Cell disruption
Biological products:
1. Extracellular
2. Intracellular
3. Periplasmic
Cells
• Gram positive bacterial cells
• Gram negative bacterial cells
• Yeast cell
• Mould cells, Cultured mammalian cells
• Cultured plant cells, Ground tissue
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Bacteria
Periplasm

Cell membrane

Cell membrane

Cell wall Peptidoglycan

Lipopolysaccharides +
proteins

•Sub-micron to 2 microns in size •Sub-micron to 1 micron in size


•Have thick cell walls, 0.02-0.04 •Cell capsule present
microns, peptidoglycan +
•Peptidoglycan layer is thin
polysaccharide+ teichoic acid
•Periplasmic space present
•Phospholipid cell membrane present
•Mechanically less robust than gm+
bacteria
•Chemically more resistant than gm+
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bacteria
Unit-I
Yeast and mould

•Yeast: 2-20 microns in size, spherical or ellipsoid


•Moulds: Bigger and filamentous
•Yeasts are unicellular while moulds are multicellular
•Very thick cell walls are present in both
•Cell wall is mainly composed of polysaccharides such as glucans,
mannans and chitins
•Plasma membranes are mainly made up of phospholipids

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Animal and plant cells
•Animal cells do not have cell walls
•Animal cells are very fragile
•Cultured animal cells are several microns in size
•Spherical or ellipsoid

•Plant cells can be bigger


•Plant cells have thick and robust cell walls mainly composed of
cellulose
•Plant cells are difficult to disrupt
•Cultured plant cells are less robust than real plant cells

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Cell disruption methods

Physical methods
• Disruption in bead mill
• Disruption using a colloid mill
• Disruption using French press
• Disruption using ultrasonic vibrations

Chemical and physicochemical methods


• Disruption using detergents
• Disruption using enzymes e.g. lysozyme
• Disruption using solvents
• Disruption using osmotic shock

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OSMOTIC AND CHEMICAL CELL LYSIS

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Bead mill

Cascading
beads
Rolling
beads Cells being
disrupted

•Disruption takes place due to the grinding action of the rolling beads and
the impact resulting from the cascading ones
•Bead milling can generate enormous amounts of heat
•Cryogenic bead milling : Liquid nitrogen or glycol cooled unit
•Application: Yeast, animal and plant tissue
•Small scale: Few kilograms of yeast cells per hour
•Large scale: Hundreds of kilograms per hour.
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Theory of grinding
Kick’s law
 r1 
dE K K f c
 E  K K f c ln 
dr r  r2 

Rittinger’s law

dE K R f c  1 1
 2 E  K R f c   
dr r  r2 r1 

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Product release from disrupted cells

Time
C  t
 1  exp   Single pass
C max  

N
C   t 
 1  exp    Multi pass
C max    

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Colloid mill
Rotor
Disrupted
cells

Cell suspension Stator

•Typical rotation speeds: 10,000 to 50,000 rpm


•Mechanism of cell disruption: High shear and turbulence
•Application: Tissue based material
•Single or multi-pass operation
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French press

Plunger

Cell Cylinder
suspension

Jet
Orifice
Impact plate

•Application: Small-scale recovery of intracellular proteins and DNA


from bacterial and plant cells
•Primary mechanism: High shear rates within the orifice
•Secondary mechanism: Impingement
•Operating pressure: 10,000 to 50,000 psig
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High Pressure Homogenizer

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Ultrasonic vibrations

Ultrasound
generator

Ultrasound tip

Cell suspension

•Application: Bacterial and fungal cells


•Mechanism: Cavitation followed by shock waves
•Frequency: 25 kHz
•Time: Bacterial cells 30 to 60 seconds, yeast cells 2 to 10 minutes
•Used in conjunction with chemical methods

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Chemical and physicochemical methods
•Detergents – Sodium dodecylsulfate( Anionic detregents)
•Sodium Sulfonate ( Anionic detregents)
•Cetylmethyl ammonium bromide(Cationic detergents)
•Tetraalkylammonium (bromide(Cationic detergents)
•Triton X-100( Non ionic detergents)
•Enzymes – Lysozymes
•Organic solvents
•Osmotic shock
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Exercise

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A rough analysis of cell contents suggests their cytoplasm contains 5% by
weight of solutes: 1% of protein of average molecular weight 45000; 1% is
soluble lipids of molecular weight 400; 1% is sugars of molecular weight 170;
and 2% is salts like KCl. What is the osmotic pressure inside these cells
relative to pure water at 37oC.

You are homogenizing a cell suspension to release an analogue of


a luteinizing hormone- releasing hormone using equipment .You
can release 50% of the total present in 8.3 litersin just 16 min.
how long will it take to release 90 % of the total present in 230
liters.

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You have just purchased a second homogenizer which is just like
the old unit and will operate in parallel to it. However, because
you did not purchase anew feed pump, you hitch both
homogenizer to the old feed pump. As a result , the upstream
pressure drops from 3000 to 2340 psi. All other variables , like
the outlet pressure and the frequency of piston oscillation are
unchanged. How much does the new unit increase your
capacity?

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Enzyme Production

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Ethanol Production

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Rittengers
Solved
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