Bilantul de materiale pentru Penicilina V

Scopul bilantului de materiale consta in determinarea cantitatii de substante utilizate in scopul

obtinerii penicilinei V. Pentru tocmirea bilantului de materiale se pleaca de la urmatoarele date
de proiectare :

-productia anuala;

-reactiile chimice care stau la baza obtinerii penicilinei V;

-randamentele individuale ale etapelor prin care se obtine in final produsul finit precum si
randamentul final al procesului.

Filtrare: = 80%

Extractie: = 94%

Reextractie: = 90%

Cristalizare: = 90%

Filtrare: = 95%

Uscare: = 98%

Productia pe an este:

Panual= 22 t/an= 22000 kg/an

Fondul anual de timp:

FAT= 330 zile 24 ore= 7920h

Durata unei sarje:

ts = tf + taux

tf durata fermentatiei, h

taux timpi auxiliari, h

ts = tf + taux

ts = 140+ 12 = 152 h

Numarul de sarje:
 FAT 7920
ns = ts = 152 = 52,10 sarje

Productia pe sarja:

P an 22000
Ps = ns = 52 = 423,076 kg/s

g = 0,80,940,90,90,950,98= 0.5671

Productia in fermentator:

Ps 423,076
Pf = g = 0,5671 = 746,034 kg/s

350g PCOOH________________________388g PCOOK

Pf =746,034 _________________________ Pf

746,034 388
Pf= 350 = 827,032

Productivitatea tulpinei:

P=40000 UI/ml

1 mg Penicilina V_______________ 1630

X mg_______________________40000

X=24,54 mg/ml

Pf 827,032
Vu = P = 24,54 = 33,70 m3

Temperatura optima: Topt = 26 C

apa = 996,8 kg/m3

Mmediu = apa Vu = 996,8 33,70 = 33593,54 kg mediu/ sarja

1.Pregatirea mediului de cultura

100kg mediu de cultura_________________2,8 kg extract porumb

33593,54 kg _________________________ x

X=940,62kg

100kg mediu de cultura________________7 kg lactoza

33593,54kg _________________________x

X =2351,54 kg

100 kg mediu de cultura ________________3 kg glucoza

33593,54 kg__________________________x

X = 1007,80kg

100kg mediu de cultura___________________0,3 kg faina de soia

33593,54kg_____________________________x

X=100,78kg

100kg mediu de cultura___________________1,3kg CaCO3

33593,54 kg____________________________x

X=436,71

100kg mediu de cultura_____________________0,6 kg KH2PO4

33593,54kg_______________________________x

X=201,56kg

100kg mediu de cultura______________________0,3kg NH4NO3

33593,54kg_______________________________x

X=100,78 kg
100kg mediu de cultura_______________________0,06kg Na2SO4

33593,54kg__________________________________x

X=20,156

100kg mediu de cultura______________________0,002kg ZnSO4

33593,54 kg _______________________________x

X=0,67kg

100kg mediu de cultura_____________________0,002kg MnSO4

33593,54_________________________________x

X=0,67kg

100kg mediu de cultura_______________________0,4 kg

33593,54kg _______________________________x

X=134,37kg

100kg mediu de cultura____________________0,8 kg

33593,54kg _____________________________x

X= 268,75kg

100kg mediu de cultura ___________________83,436kg apa

33593,54kg_____________________________x

X=28029,14kg

Nr. Materiale Kg/s % Materiale Kg/s %

ctr. intrate iesite
 1. Extract porumb 940,62 2,8 Extract porumb 940,62 2,8
2. Lactoza 2351,54 7 Lactoza 2351,54 7
3. Glucoza 1007,80 3 Glucoza 1007,80 3
4. Faina de soia 100,78 0,3 Faina de soia 100,78 0,3
5. CaCO3 436,71 1,3 CaCO3 436,71 1,3
6. KH2PO4 201,56 0,6 KH2PO4 201,56 0,6
7. NH4NO3 100,78 0,3 NH4NO3 100,78 0,3
8. Na2SO4 20,156 0,06 Na2SO4 20,156 0,06
9. ZnSO4 0,67 0,002 ZnSO4 0,67 0,002
10. MnSO4 0,67 0,002 MnSO4 0,67 0,002
11. Ac. fenoxiacetic 134,37 0,4 Ac. fenoxiacetic 134,37 0,4
12. Na2S2O3 268,75 0,8 Na2S2O3 268,75 0,8
13. Apa 28029,14 83,436 Apa 28029,14 83,436

Total 33593,54 100 Total 33593,54 100

Deoarece in timpul sterilizarii o parte din componentii mediului de cultura se degradeaza

urmatorii componenti se iau in exces de 10 %: glucoza, lactoza, extractul de porumb si faina
de soia.

Nr. Materiale Kg/s % Materiale Kg/s %

ctr. intrate iesite
1. Extract porumb 1034,682 3,08 Extract porumb 940,62 2,8
2. Lactoza 2586,694 7,7 Lactoza 2351,54 7
3. Glucoza 1108,58 3,3 Glucoza 1007,80 3
4. Faina de soia 110,858 0,33 Faina de soia 100,78 0,3

940,62 extract porumb____________________2,8

X_____________________________________3,08
X=1034,682 kg/s extract de porumb

2351,54 lactoza__________________7

X_____________________________7,7

X=2586,694 kg/s lactoza

1007,80 glucoza_____________________3

X_________________________________3,3

X=1108,58 kg/s glucoza

100,78faina de soia______________________0,3

X____________________________________0,33

X=110,858 kg/s faina de soia

5. CaCO3 436,71 1,3 CaCO3 436,71 1,3

6. KH2PO4 201,56 0,6 KH2PO4 201,56 0,6
7. NH4NO3 100,78 0,3 NH4NO3 100,78 0,3
8. Na2SO4 20,156 0,06 Na2SO4 20,156 0,06
9. ZnSO4 0,67 0,002 ZnSO4 0,67 0,002
10. MnSO4 0,67 0,002 MnSO4 0,67 0,002
11. Ac. fenoxiacetic 134,37 0,4 Ac. fenoxiacetic 134,37 0,4
12. Na2S2O3 268,75 0,8 Na2S2O3 268,75 0,8
13. Apa 27589,06 82,126 Apa 28029,14 83,436

Total 33593,54 100 Total 33593,54 100

2. Etapa de sterilizare
 Nr. Materiale Kg/s % Materiale Kg/s %
ctr. intrate iesite
1. Extract porumb 1034,682 3,08 Extract porumb 940,62 2,8
2. Lactoza 2586,694 7,7 Lactoza 2351,54 7
3. Glucoza 1108,58 3,3 Glucoza 1007,80 3
4. Faina de soia 110,858 0,33 Faina de soia 100,78 0,3
3. Fermentatia

3.1. Necesarul de aer

1L= 10-3 m3 aer_______________10-3 m3 mediu de cultura

Vaer______________________________________ Vu=33,7 m3

103
Vaer= 103 33,7=33,7 m3 aer/ m3 mediu de cultura

1min___________Vaer=33,7 m3 aer

tf= 8400_________Vaer

8400 33,7
Vaer= 1 =283080 m3 aer

p=1,1 atm

p0=1 atm

T0=273 K

T=299 K

0=1,293 kg/m3

T0 p 273 1,1

aer=0 T p0 = 1,293 299 1 =1,2986 kg/m3

Maer=Vaer= 1,2986283080=367607,688 kg aer/sarja

3.2. Biomasa

10-3 ________________100g celule

Vu=33,7_____________Mbiomasa

100 33,7
Mbiomasa= 103 = 3370 kg biomasa/sarja

3.3 Apa evaporata

1 kg aer preia ________________________0,01 kg H2O

M=367607,688 kg aer__________________ M H2O

MH2O evaporata=3676,077 kg

Lichidul de fermentatie:

Mldf=Mmdc +Minocul-MH2Oevaporata-Mbiomasa

Minocul= 10%Mmdc=10%33593,54=3359,354

Mmdc= 90%Mmdc= 30234,186

Mldf=30234,186+3359,354-3676,077-3370 =26547,463

MARIMI INTRATE Kg / sarja MARIMI IESITE Kg / sarja

 Mediu de cultura 30234,186 Lichid de fermentatie 26547,463

Inocul 3359,354 Biomasa 3370

Aer 367607,688 Aer 367607,688

Apa evaporate 3676,077

TOTAL 401201,228 TOTAL 401201,228

4.Filtrarea

=80%=0,8

Precipitatul retine 20 % din lichidul de fermentatie

Mpp = Mbiomasa+MH2Oprecipitat

Mpp = Mbiomasa+0,2Mpp

M biomasa 3370
Mpp = 0,8 = 0,8 = 4212,5 kg/sarja

Mfiltrat=Mldf -0,2Mpp = 26547,463 0,24212,5 = 25704,963 kg/sarja

MARIMI INTRATE Kg / sarja MARIMI IESITE Kg / sarja

Lichid de fermentatie 26547,463 Precipitat 4212,5

Biomasa 3370 Filtrat 25704,963

Penicilina V (produs (661,6256)

util)
TOTAL 29917,463
TOTAL 29917,463
5. Extractia

=0,94

Extractia se realizeaza utilizand acetat de butil in raport de 1:3 cu filtratul.

2388 98 2350 174

PCOOK + H2SO4 PCOOH + K2SO4

661,63 x y z

X=83,55

Y=596,83 Y=0,94*596,83=561,02

Z=148,35

pH=6,7

pH=2

pH=6,7-2= 4,7

pH=- log[H+]

4,7= -log[H+] [H+]=1,99510-5 ioni H+ / l

1mol H2SO4____________________2 H+

t_____________________________1,99510-5 ioni H+ / l

t=9,97510-6 moli/l

1l=10-3 m3 filtrat_______________________________ 9,97510-6 moli/l

Vf =33,7 m3__________________________________ u moli H2SO4 / sarja

u= 0,336 moli H2SO4 / sarja = 33610-6 kmoliH2SO4/ sarja

md H2SO4 = x+u980,001 = 83,55+33610-6 98=83,58kg H2SO4 100%

Pentru extractie se foloseste H2SO4 4% :

md
c= md+mapa * 100

md=83,58 kg H2SO4 100%

 md 83,58
ms= 4 100= 4 100= 2089,5 H2SO4 4 %

Mapa= ms-md= 2089,5-83,58=2005,92kg H20 /sarja

Macetat de butil= Mfiltrat/3=25704,963/3=8568,321 kg/sarja

Mextract=98%Macetat+MPVextrasa=8396,954+561,02=8957,974

Mrafinat=2%Macetat+MPvneextrasa+MK2SO4+Mapa din sol. H2SO4+(Mfiltrat-MPVextrasa)= 171,366 +

35,81+148,35+2005,92+(25704,963-661,63) = 36362,753

Mrimi intrate Kg / sarja Mrimi ieite Kg / sarja

Filtrat 25704,963 Extract 8957,974

Acetat de butil 8568,321 (Penicilina V extrasa) (561,02)

H2SO4 4% 2089,5 Rafinat 27404,779

TOTAL 36362,784

TOTAL 36362,753

6.Reextracia

= 90% = 0.9

Reextracia se realizeaz cu K2CO3 10% n exces de 10%.

2PCOOH + K2CO3 2PCOOK+CO2+H2O

2*350.138...........2*388.4418

561,02....X...........Y.Z.T

X=110,6010 kg K2CO3/arj
 Y=621,9307 kg Penicilina V Y=0,9*621,9307 = 559,7376kg Pv reextras

Z=35,2641 kg CO2 Z=0,9*35,2641 = 31,7376 kg CO2

T=14,4262 kg H2O T=0,9*14,4262 = 12,9836 kg H2O

X=X+10%=X*1.1=110,6010 *1.1=121,6611 kg K2CO3 100%

K2CO3 exces=0.1*X=0,1*121,6611 = 12,16611 kg/arj

100
ms=X* 10 = 121,6611 *10=1216,611 kg K2CO3/arj

Mapa= ms-X=1216,611 - 121,6611 =1094,9499 kg H2O din carbonat

Datorit excesului exist K2CO3 nereacionat:

a= 0,1*X=0,1*110,6010 =11,0601kg K2CO3 nereacionat

Solvent:

Msolvent=Mextract-MPvextras-2%*Macetat

=8957,974-(561,02 0,9 )-(0,02*8568,321)=8281,6895 kg/arj

Soluia carbonat:

Msol.carbonat=MPVreextrasa+MH2Odincarbonat+MK2CO3nereac.+MK2CO3ex.+Mapareacie+MCO2+(0,02*Macetat
0,98 )

= 559,63 +1094,9499 +11,0601 + 12,1661 + 12,9836 +31,7376 +(0,02*8568,321*0,98)

= 1894,0013 kg/arj

Tabel. Bilan de materiale

Mrimi intrate Kg/arj Mrimi ieite Kg/arj

Extract 8957,974 Solvent-acetat epuizat 8281,6895
K2CO3 10% 1216,611 Soluie carbonat 1894,0013

TOTAL 10174,585 TOTAL 10175,6908

7.Cristalizarea

= 90% = 0.9

PCOOK + HCl PCOOH + KCl

388...............36,5..........................350.................74,5

559,7376........x..............................y.....................z

X=52,6557 x=47,3901

Y=504,9179 y=454,4261

Z=107,4753 z=96,7278

Se utilizeaza HCl 20% in exces 5% :

x (1+0,05) =x1,05=52,6557 1,05 = 55,2884 kg HCl 100%

ms=55,2884/20 100= 276,4424

md+mapa=276,4424 mapa= 276,4424-55,2884=221,1540

Ape acide= Msol carbonat MPvprecipitat +Mapa + MHCl exces + MHCl nereactionat + MKCl

= 1894,0013- 0,9559,7376 +221,1540+2,6327+0,1 52,6557 +96,7278

= 1716,0175

Marimi intrate Kg/sarja Marimi iesite Kg/sarja

Sol carbonat 1894,0013 PV precipitat 454,4261
Penicilina V
HCl 20% 276,4424 Ape acide 1716,0175
Total 2170,4437 Total 2170,4436

8.Filtrarea . Spalarea pe filtru

= 95 % = 0.95

Precipitatul contine 20% umiditate :

MPVf=0,95 454,4261 = 431,7047

MPP = PV + 0,2 Pp = PV

0,8Mpp = MPVf

Mpp= MPVf / 0,8 = 431,7047/ 0,8=539,6308

Filtrat apos:

Mfiltrat apos= Mape acide 0,2Mpp +0,05PV= 1716,0175- 0,2539,6308 + 0,05 454,4261
=1630,8126

Cristalele se spala pe filtru cu butanol si cloroform in raport de 1:5 fata de Mpp

Mbutanol = Mcloroform = Mpp / 5 = 539,6308/5= 107,9261/2= 53,9630

Marimi intrate Kg/sarja Marimi iesite Kg/sarja

penicilina V pp 454,4261 Precipitat 539,6308
Ape acide 1716,0175 Filtrate apos 1630,8126
Butanol 53,9630 Butanol 53,9630
Cloroform 53,9630 cloroform 53,9630
TOTAL 2278,3697 TOTAL 2278,3695

9.Uscarea

= 98 % = 0.98

Umiditatea este de 20% :

Mcloroform= 0,2 Pp +MPV pierduta = 0,2539,6308 + 0,02431,7047 = 116,5602

Marimi intrate Marimi iesite

precipitat 539,6308 Penicilina V 423,0706
Cloroform evaporate 116,5602
TOTAL 539,6308 TOTAL 539,6308