Demonstration of the use of windows of operation to visualize the effects of fouling on the performance of a chromatographic step

The high resolution afforded by packed bed chromatography makes it an indispensable operation in the downstream processing of therapeutic molecules. Packed bed performance is however inherently susceptible to changes in feed stream characteristics and fouling processes. The impact of fouling is seldom considered during the early stages of bioprocess development which is concerned with the selection of purification conditions. Instead these are performed with rigorously clarified feeds. Under such conditions, chromatography is effectively treated as an isolated step, independent from its preceding unit operations. In this study, we demonstrate how windows of operation could be used to visualize the impact of changes in the preceding clarification step on the fouling response of a subsequent cation exchange capture step. Laboratory columns (2,5 and 12 cm height) were subjected to varying fouling challenges of Escherichia coli lysate containing different amounts of solids carried over from the previous step. Changes in trans‐column pressure drop and breakthrough of the target protein (Fab′) were monitored. The limits of operability of the resin were determined with respect to the process material's properties. This information was used to extract the parameters for the adsorption kinetics used in the general rate (GR) model to create windows of operation for manufacturing scale operation. © 2011 American Institute of Chemical Engineers Biotechnol. Prog., 2011     

The effect of column verticality on separation efficiency in expanded bed adsorption

The effect of column verticality on liquid dispersion and separation efficiency in expanded bed adsorption columns was investigated using 1 and 5 cm diameter columns. Column misalignment of only 0.15° resulted in the reduction of the Bodenstein number from 140 to 50 for the 1 cm dia. column and from 75 to 45 for the 5 cm dia. column. This degree of misalignment was not detectable by visual assessment of adsorbent particle movement within the column. Depending on the relative importance of transport limitations, kinetic limitations and dispersion to any specific separation, this increase in dispersion with column alignment can significantly affect separation efficiency. Pure protein breakthrough profiles resulting from the application of bovine serum albumin onto STREAMLINE Q XL demonstrated that, at 10% breakthrough, 7.8% more protein could be applied to a vertical 1 cm dia. column compared to the same column misaligned by 0.15°. When an unclarified yeast homogenate was applied to a 1 cm dia. vertical column packed with STREAMLINE DEAE, 10% breakthrough of glucose-6-phosphate dehydrogenase (G6PDH) corresponded to a load 55% greater compared to the same column aligned 0.185° off-vertical. The G6PDH breakthrough curves for vertical and 0.15° off-vertical runs performed using a 5 cm column were essentially indistinguishable.     

Studies on protein adsorption in a vortex flow reactor

The performance of a vortex flow reactor (VFR) with suspended particles for protein adsorption was studied under varying operating conditions, and resin volume fractions. The VFR behaved as an expanded bed in the regimen of laminar vortices flow. Streamline DEAE was used for bovine serum albumin (BSA) adsorption. Expanded bed VFR experiments were performed with varying geometric aspect ratios (14.6, 28.6 and 40.0) and axial superficial velocity (100–300 cm h⁻¹) to investigate their influence on productivity and dynamic capacity. The results are compared with literature data on an expanded bed column (EBC). Adsorption breakthrough curves were fitting to a simple two-parameter model.     

Effect of protein fouling on filtrate flux and virus breakthrough behaviors during virus filtration process

Virus filtration process is used to ensure viral safety in the biopharmaceutical downstream processes with high virus removal capacity (i.e., >4 log₁₀). However, it is still constrained by protein fouling, which results in reduced filtration capacity and possible virus breakthrough. This study investigated the effects of protein fouling on filtrate flux and virus breakthrough using commercial membranes that had different symmetricity, nominal pore size, and pore size gradients. Flux decay tendency due to protein fouling was influenced by hydrodynamic drag force and protein concentration. As the results of prediction with the classical fouling model, standard blocking was suitable for most virus filters. Undesired virus breakthrough was observed in the membranes having relatively a large pore diameter of the retentive region. The study found that elevated levels of protein solution reduced virus removal performance. However, the impact of prefouled membranes was minimal. These findings shed light on the factors that influence protein fouling during the virus filtration process of biopharmaceutical production.     

A monolith purification process for virus-like particles from yeast homogenate

Monoliths are an alternative stationary phase format to conventional particle based media for large biomolecules. Conventional resins suffer from limited capacities and flow rates when used for viruses, virus-like particles (VLP) and other nanoplex materials. The monolith structure provides a more open pore structure to improve accessibility for these materials and better mass transport from convective flow and reduced pressure drops. To examine the performance of this format for bioprocessing we selected the challenging capture of a VLP from clarified yeast homogenate. Using a recombinant Saccharomyces cerevisiae host it was found hydrophobic interaction based separation using a hydroxyl derivatised monolith had the best performance. The monolith was then compared to a known beaded resin method, where the dynamic binding capacity was shown to be three-fold superior for the monolith with equivalent 90% recovery of the VLP. To understand the impact of the crude feed material confocal microscopy was used to visualise lipid contaminants, deriving from the homogenised yeast. It was seen that the lipid formed a layer on top of the column, even after regeneration of the column with isopropanol, resulting in increasing pressure drops with the number of operational cycles. Removal of the lipid pre-column significantly reduces the amount and rate of this fouling process. Using Amberlite/XAD-4 beads around 70% of the lipid was removed, with a loss of VLP around 20%. Applying a reduced lipid feed versus an untreated feed further increased the dynamic binding capacity of the monolith from 0.11 mg/mL column to 0.25 mg/mL column.     

Continuous Biosorption of Pb,Cu, and Cd by Phanerochaete chrysosporium in a Packed Column Reactor

The dynamic removal of lead, copper and cadmium in a single component system by Phanerochaete chrysosporium was studied in packed columns. The packed columns consisted of biomass of P. chrysosporium immobilized on polyurethane foam cubes. The performances of packed columns were described through the concept of breakthrough and the values of column parameters predicted as a function of bed depth. The column biosorption data were evaluated in terms of maximum (equilibrium) capacity of the column, the amount of metal loading and the yield of the process. The maximum capacities for lead, copper and cadmium were 70.7, 43.7 and 70.8 mg, respectively, and their yields were 39.2, 40.6 and 41%, respectively. The kinetic and mass transfer aspects of the dynamic removal of the three metals were studied using three mathematical models commonly used to describe the column performance in adsorption processes. Column studies showed good agreement between the experimental data and the simulated breakthrough curves obtained with Adams-Bohart or the Wolborska model and the Clark model. While the initial segment of the breakthrough curve was defined by the Adams-Bohart and Wolborska models, the whole breakthrough curve was well predicted by the Clark model for all the three metals studied.     

Continuous biosorption of cadmium by Moringa olefera in a packed column

The biosorption of Cd(II) by Moringa oleifera using a batch system and a continuous up flow mode in a fixed bed column was studied. Batch adsorption experiments were performed as a function of pH, biosorbent dose, contact time, volume of the solution, and initial metal concentration. The adsorption isotherms obtained fitted well into the Freundlich and Langmuir isotherms. The dynamic removal of cadmium by powdered seed of the Moringa oleifera was studied in a packed column. The effect of bed height (4 and 8 cm) and flow rate (2 and 5mL/min) on biosorption process was investigated and the experimental breakthrough curves were obtained. Results showed that by increasing the bed height and decreasing the flow rate, the breakthrough and exhaustion times increased. The break-through time was considered as a measure of the column performance. The maximum break-through time of 320 min was achieved at the operating condition of 2 mL/min influent flow rate and bed height of 8 cm.     

Biosorption of copper by marine algae Gelidium and algal composite material in a packed bed column

Marine algae Gelidium and algal composite material were investigated for the continuous removal of Cu(II) from aqueous solution in a packed bed column. The biosorption behaviour was studied during one sorption–desorption cycle of Cu(II) in the flow through column fed with 50 and 25 mg l⁻¹ of Cu(II) in aqueous solution, at pH 5.3, leading to a maximum uptake capacity of ≈13 and 3 mg g⁻¹, respectively, for algae Gelidium and composite material. The breakthrough time decreases as the inlet copper concentration increases, for the same flow rate. The pH of the effluent decreases over the breakthrough time of copper ions, which indicates that ion exchange is one of the mechanisms involved in the biosorption process. Temperature has little influence on the metal uptake capacity and the increase of the ionic strength reduces the sorption capacity, decreasing the breakthrough time. Desorption using 0.1 M HNO₃ solution was 100% effective. After two consecutive sorption–desorption cycles no changes in the uptake capacity of the composite material were observed. A mass transfer model including film and intraparticle resistances, and the equilibrium relationship, for adsorption and desorption, was successfully applied for the simulation of the biosorption column performance.     

Fixed-Bed Studies on Removal of Arsenic from Simulated Aqueous Solutions Using Chitosan Nanoparticles

Arsenic is a toxic element and may be found in natural as well as in industrial water; therefore, before using water for drinking purpose, its proper treatment is required. Thus, the aim of this work was to evaluate the potential of chitosan nanoparticles, in a continuous-flow method, for the removal of arsenic (III) and (V) from aqueous solutions. All experiments were conducted in fixed-bed columns. Experiments were carried out as a function of varying liquid flow rate (0.3–1.0 ml/min), initial metal concentration (0.5–1.5 mg/L), and bed height (3–9 cm) of adsorbent. The total adsorbed quantity, equilibrium uptake, and total percentage removal of arsenic ions were determined by evaluating the breakthrough curves obtained at different flow rates, initial concentrations, and bed heights. The results showed that the column performed well at the lowest flow rate. Also, column bed capacity and exhaustion time were found to increase with increasing bed height. When initial metal ion concentration was increased from 0.5 to 1.5 mg/L, the corresponding adsorption bed capacity decreased from 0.076 to 0.028 mg/g. The bed depth service time model (BDST) model was used to analyze the experimental data and the model parameters were evaluated. The calculated values of N _o and K _a were found to be 19.28 × 10^?2 mg/L and 0.662 L/mg·min, respectively. Good agreement was found between the experimental breakthrough curves and the model predictions.     

Bench-scale and packed bed sorption of methylene blue using treated olive pomace and charcoal

A combination of olive pomace after solvent extraction and charcoal produced from the solid waste of olive oil press industry was used as an adsorbent for the removal of methylene blue (MB) dye from aqueous solutions. Batch tests showed that up to 80% of dye was removed when the dye concentration was 10 mg/ml and the sorbent concentration was 45 mg/ml. An increase in the olive pomace concentration resulted in greater dye removal from aqueous solution, and an increase in MB dye concentration at constant adsorbent concentration increased the dye loading per unit weigh of adsorbent. In the kinetic of the adsorbent process, the adsorption data followed the second-order kinetic model better than first order kinetic model. Charcoal showed higher sorption capacity (uptake) than that of olive pomace. In the fixed bed adsorption experiment, the breakthrough curves showed constant pattern behavior, typical of favorable isotherms. The breakthrough time increased with increasing bed height, decreasing flow rate and decreasing influent concentration and methylene blue dye uptake. The uptake of MB dye was significantly increased when a mixture of olive pomace and charcoal was packed in the column in a multi-layer fashion. Different models were used to describe the behavior of this packed-sorption process.     

Nanofiber adsorbents for high productivity downstream processing

Electrospun polymeric nanofiber adsorbents offer an alternative ligand support surface for bioseparations. Their non‐woven fiber structure with diameters in the sub‐micron range creates a remarkably high surface area. To improve the purification productivity of biological molecules by chromatography, cellulose nanofiber adsorbents were fabricated and assembled into a cartridge and filter holder format with a volume of 0.15 mL, a bed height of 0.3 mm and diameter of 25 mm. The present study investigated the performance of diethylaminoethyl (DEAE) derivatized regenerated cellulose nanofiber adsorbents based on criteria including mass transfer and flow properties, binding capacity, and fouling effects. Our results show that nanofibers offer higher flow and mass transfer properties. The non‐optimized DEAE‐nanofiber adsorbents indicate a binding capacity of 10% that of packed bed systems with BSA as a single component system. However, they operate reproducibly at flowrates of a hundred times that of packed beds, resulting in a potential productivity increase of 10‐fold. Lifetime studies showed that this novel adsorbent material operated reproducibly with complex feed material (centrifuged and 0.45 µm filtered yeast homogenate) and harsh cleaning‐in‐place conditions over multiple cycles. DEAE nanofibers showed superior operating performance in permeability and fouling over conventional adsorbents indicating their potential for bioseparation applications. Biotechnol. Bioeng. 2013; 110: 1119–1128. © 2012 Wiley Periodicals, Inc.     

Theoretical investigation of axial and local particle size distribution on expanded bed adsorption process

The general rate model was developed and solved to describe protein adsorption in an expanded bed. The model takes into account axial variation of bed porosity, particle size distribution (PSD), external and intraparticle mass transfer, and dispersion in liquid and solid phase. The analysis of the influence of the model parameters on dynamic capacity (DC) was investigated. The simulation results showed that major impact on dynamic capacity is exerted by intraparticle mass transfer (particle diameter and pore diffusivity). The external mass transfer resistance and dispersion parameters have secondary effect on DC. The replacement of axial PSD by the mean particle diameter results in error in calculation of DC, which increases remarkably with the increase of mean particle diameter. The PSD can promote a very slow approaching of plateau concentration by breakthrough curves. It was shown also that axial bed porosity variation could be replaced by average porosity with negligible error for DC calculations.     

Expanded bed adsorption at production scale: Scale-up verification, process example and sanitization of column and adsorbent

Expanded bed adsorption is a technique for recovery of biomolecules directly from unclarified feedstocks. The work described here demonstrates that expanded bed adsorption is a scaleable technique. The methods used to test scaleability were “determination of degree of bed expansion”, “determination of axial dispersion” and “determination of protein breakthrough capacity”. The performance of a production scale expanded bed column with 600?mm diameter was tested using these methods and the results were found to be consistent with the results obtained from lab scale and pilot scale expanded bed columns. The scaleability and function of the expanded bed technique was also tested by performing a “process example”: a purification mimicking a real process using a yeast culture spiked with bovine serum albumin as feedstock. The results show that the 600?mm diameter production scale column was as efficient as a 25?mm diameter lab scale column in recovering bovine serum albumin from the unclarified yeast culture. The production scale runs were fully automated using a software controlled system containing an adaptor position sensor and an adsorbent sensor. A cleaning study was performed which showed that after use of a proper cleaning protocol, no surviving microorganisms could be detected in the column or in the adsorbent.     

Development and scale up of a capture step (expanded bed chromatography) for a fusion protein expressed intracellularly in Escherichia coli

A capture step was developed using the expanded bed adsorption technology to separate a protein of interest on a cation exchanger from a crude Escherichia coli homogenate. This method was developed in bench-top scale using a STREAMLINE 25 column (Amersham Pharmacia Biotech, Sweden) and STREAMLINE SP. The development was based on earlier experiments performed in a packed bed column (SP-Sepharose FF) to investigate the conditions for sample application, wash and elution. The packed bed method was transformed into an expanded bed method by slightly modifying the wash procedure and cleaning in place (CIP). This method was then scaled-up to pilot scale and used for production of the fusion protein according to cGMP.The yield over the step in pilot scale was 70-85% compared with only 30-50% in small scale. Pressure build-up, attachment of biomass to the adsorbent and collapses of the expanded bed were phenomena seen in small scale but not in pilot scale. The scale-up of the step significantly improved the performance of the step.     

Evaluation of the effect of in-bed sampling on expanded bed adsorption

An expanded bed adsorption (EBA) column (5 cm diameter) has been modified to allow the abstraction of liquid samples from various positions along the height of an expanded bed. As the adsorbent particles were fluidized, in-bed monitoring of key component concentrations during feedstock application, washing and elution was achieved by the withdrawal of liquid samples from the voids within the expanded bed through ports along the wall of the column. Component levels in the withdrawn streams can be assayed using on-line analytical chromatography or samples can be collected and assayed off-line. On-line monitoring can be used to control the duration of the loading stage and as a tool to provide information about the hydrodynamic and adsorption/desorption processes that occur during expanded bed adsorption. Studies of residence time distributions indicated that the modifications to the column do not significantly affect liquid dispersion. Using the adsorption of glucose-6-phosphate dehydrogenase from yeast homogenate on Streamline DEAE as a model system, comparison of breakthrough curves for runs when in-bed monitoring was and was not performed also suggested that separation efficiency is not appreciably affected by in-bed sampling.     

Application of equilibrium and mass transfer models to dynamic removal of Cr(VI) ions by Chitin in packed column reactor

The dynamic removal of hexavalent chromium by chitin flakes was studied in a packed column reactor. The values of column parameters were predicted as a function of flow rate, bed depth, particle size and inlet metal ion concentration. On evaluating the breakthrough curves, sorption isotherms were obtained and modelled according to the Langmuir, the Redlich–Peterson and the Freundlich models. Kinetic and mass transfer aspects of the dynamic removal of Cr(VI) ions by chitin were investigated using several mathematical models. Column studies showed a good correlation between the experimental data and the calculated breakthrough curves obtained by the Adams–Bohart or the Wolborska models and the Clark model. The simulation of the whole breakthrough curve was effective with the Clark model, but the breakthrough was best predicted by Adams–Bohart, or related derived models.     

Examination of protein adsorption in fluidized bed and packed bed columns at different temperatures using frontal chromatographic methods

The influences of various experimental parameters on the dynamic adsorption capacity (DAC) and the dynamic adsorption rate (DAR) of a biomimetic affinity silica-based adsorbent in fluidized and packed bed columns operated under plug flow conditions and at different temperatures have been investigated with different inlet concentrations of hen egg white lysozyme (HEWL) and human serum albumin (HSA). The DACs as well as the DARs of both the fluidized and packed beds were examined at 10% saturation (i.e., at the QB value) and the experimental data compared with the corresponding data obtained from batch equilibrium adsorption procedures. Parameters examined included the fluid superficial velocity and protein concentration and their effect on the binding capacity and column efficiency. Consistent with various results reported from this and other laboratories on the behavior of biospecific affinity adsorbents derived from porous silica and zirconia particles, adsorbents prepared from Fractosil 1000 were found to exhibit appropriate rheological characteristics in fluidized bed systems under the experimental conditions. Moreover, changes in temperature resulted in a more significant effect on the breakthrough profiles of HSA compared to HEWL with the immobilized Cibacron Blue F3G-A with Fractosil 1000 adsorbent. This result suggests that temperature effects can possibly be employed profitably in some processes as part of a strategy to enhance column performance with fluidized bed systems for selective recovery of target proteins. At relatively low superficial velocities of the feed, the DARs with HEWL and HSA were similar for both the fluidized and packed bed column systems, whereas, at high superficial velocities, the DARs for these proteins were larger with the packed bed columns.     

The use of rapid on-line monitoring of products and contaminants from within an expanded bed to control separations exhibiting fast breakthrough characteristics and to maximize productivity

Conventional control of expanded-bed adsorption (EBA), like that of packed-bed chromatography, is based upon off-line measurements of the column eluant. The relatively high-void volumes in EBA systems means that this approach can lead to significant performance losses caused by the inability to achieve tight control of breakthrough. This problem is made worse if the product has a fast breakthrough characteristic or if it is necessary to operate to low levels of product loss. In this article we examine the utility of constant on-line monitoring from within the expanded bed using stopped-flow analysis (SFA) to provide data for the control of the expanded-bed operation. A modified Streamline 50 column with side ports that enable sampling along the expanded axis of the bed was used. Comparisons between off-line and on-line measurements are presented, showing how the advanced monitoring method can lead to better control and to an analysis of breakthrough development within the bed. The expanded bed was used to purify alcohol dehydrogenase from homogenized suspensions of bakers' yeast. Accurate control of breakthrough to 10% of the target enzyme was achieved using a SFA control system with a response time of 40 seconds. On-line data compared well to assays carried out off-line on the outlet stream for both the product enzyme (ADH), total protein, RNA, and cell debris levels (via UV 650 nm). This information was used to generate a series of graphs with which to track the EBA process in real-time. Results showed that bed utilization was not linear along the bed axis so that, for example, 60% of ADH is bound in the bottom 33% of the column during loading.     

Experimental and modeling studies on the sorption breakthrough behaviors of butanol from aqueous solution in a fixed-bed of KA-I resin

Removal of biobutanol from acetone-butanolethanol (ABE) fermentation broth can be achieved by fixed-bed sorption by means of KA-I resin, and the relevant breakthrough curves would provide much valuable information to help design a continuous fixed-bed sorption process in field application. In the present study, the effects of several important design parameters, i.e., initial butanol concentration (C _f: 3.0 ～ 30.0 g/L), inlet flow rate (Q _f: 0.5 ～ 5.5 mL/min) and adsorbent bed height (Z: 4.2 ～ 18.0 cm), on the adsorption breakthrough curves of KA-I resin in a fixed-bed column were investigated. It was found that the amount of adsorbed butanol at breakthrough point was increased with an increase in the value of C _f and Z; and with decrease in the value of Q _f. However, the maximum sorption capacities of butanol at saturated point were basically unchanged. Three well-established fixed-bed adsorption models, namely Thomas, Yoon-Nelson and Adams-Bohart, were applied to predict the breakthrough curves and to determine the characteristic parameters of fixed-bed column, which are the basis for the process design at a real scale. Good agreement between the theoretical breakthrough curves and the experimental result were observed using Thomas and Yoon-Nelson models.