SuperPro Designer Examples
SuperPro Designer is shipped with more than seventy thorough examples covering a variety of industries and applications. In addition, we are constantly adding new ones. The examples are grouped into folders based on the target industry and application. A brief description of each example follows below. You can test-drive all these examples by downloading the functional evaluation edition of SuperPro Designer. Each example comes with a detailed ReadMe file in Word format that describes the process, highlights the results of the analysis and elaborates on various modeling concepts. Descriptive videos are available for some of the examples (the links are provided below). Click here to download a zip file that includes the very latest example files of SuperPro Designer. We strongly recommend that you study the examples that are of interest to you. That is the best way to become an expert user of the tool. If you install SuperPro Designer on your computer, the default installation path of the Examples folder is C:\ Users \ Public \ Public Documents \ Intelligen \ SuperPro Designer \ v# \ Process Library \ Examples
Pharmaceuticals Folder
| Example Name | Example Description |
|---|---|
| Bio-Collagen | This example analyzes the production of human collagen via the fermentation of genetically engineered yeast (bio-collagen). In this process, the yeast secretes collagen peptides into the extracellular medium, reaching a concentration of 17.5 g/L after five days of cultivation. Subsequently, the biomass is separated using centrifugation, and small molecule impurities are removed using crossflow filtration. The collagen solution undergoes purification through acetone precipitation followed by ion-exchange chromatography. The final product solution is concentrated using thin-film evaporation and then freeze-dried. Each batch yields 154 kg of collagen powder, amounting to an annual production of 50 metric tons. |
| Blood Plasma Fractionation | This example analyzes the manufacturing of therapeutic proteins from blood plasma. Plasma contains numerous proteins, such as albumin, factor VIII, IgG, etc., that exert important physiological functions. The plasma proteins can be separated, purified, and used to treat a variety of health conditions. The present example includes two SuperPro Designer models, one focusing on the production of Albumin and the other on the production of IgG. |
| Cannabinoids via Fermentation | This example analyzes the production of a rare cannabinoid (cannabigerolic acid) via fermentation using a genetically engineered yeast. Cannabinoids find numerous applications for reduction of pain and inflammation, relaxation, as supplements in cosmetic products, etc. The manufacturing plant analyzed in this example produces 15,000 kg of cannabigerol per year. The estimated capital investment (CAPEX) for such a plant is around $44 million. Two scenarios are modeled and evaluated using SuperPro Designer, one using ethyl acetate for product extraction and another using supercritical CO2. |
| mRNA Vaccine | This example analyzes the industrial production of messenger RNA (mRNA) vaccines such as those developed against COVID-19 by Moderna and Pfizer / BioNTech. mRNA is synthesized in a cell-free (enzymatic) reaction (in vitro transcription), which is carried out in a rocking bioreactor. The product is purified by ultrafiltration / diafiltration, affinity (oligo-dT) chromatography, and hydrophobic interaction chromatography. The purified mRNA is encapsulated within lipid nanoparticles (LNPs) using microfluidic mixers and formulated with an appropriate buffer. The process analyzed produces one billion doses of mRNA vaccine per year. |
| Plasmid DNA (pDNA) | This example models the industrial production of pharmaceutical grade plasmid DNA (pDNA). Plasmids are circular DNA molecules that find applications in gene therapy, vaccines, and molecular biology research. pDNA is produced in bacteria Escherichia coli by fed-batch fermentation. The cells are disrupted by alkaline lysis to release the pDNA. Most contaminants are subsequently removed by selective precipitation. pDNA is purified by ultrafiltration / diafiltration, anion-exchange chromatography and hydrophobic interaction chromatography. The process analyzed in this example produces 307 kg of purified pDNA per year. |
| Polysaccharide Vaccines (for Pneumonia and Meningitis) | This example analyzes the production of bacterial polysaccharide vaccines such as those used to protect against pneumonia and meningitis. The bacterial polysaccharide is produced by fermentation in batch mode using a complex culture medium. Subsequently, the polysaccharide is released from the cells by treatment with sodium hydroxide, which also inactivates the bacteria. The product is then purified by ethanol precipitation, crossflow filtration, and depth filtration steps. A total of 31.6 kg of polysaccharide is produced per year, corresponding to 50 million doses of a 23-valent polysaccharide vaccine. |
| Viral Vaccines for COVID-19 and other Infectious Diseases | This example analyzes the manufacturing of whole virus vaccines including inactivated virus vaccines, live attenuated vaccines and viral vector vaccines, such as those developed against COVID-19 by Oxford / AstraZeneca and Johnson & Johnson. The virus is produced in a suspension culture of animal cells in a stirred-tank bioreactor. After viral replication, the cells are lysed using a detergent, and the released DNA is selectively precipitated with a cationic compound. The suspended solids are removed by centrifugation and depth filtration. The clarified product solution goes through ultrafiltration-diafiltration, anion-exchange chromatography, and formulation. The process generates 400 million vaccine doses per year. |
| Allogeneic Cell Therapy | This example analyzes the production of Allogeneic Stem Cells for Cell Therapy applications. The results include material and energy balances, equipment sizing, capital and operating cost estimation. Note that cell therapy is a very new field and therefore there is a great deal of variation in the cell production and purification processes that are currently in use by various organizations. |
| Cell and Gene Therapy | This example analyzes the manufacturing of autologous cell therapy products and viral vectors. Viral vectors are used as raw materials in cell therapy manufacturing and as drugs in gene therapy. The cell therapy process starts with white blood cells collected from the patient. The material is enriched in T cells that are subsequently activated, genetically modified with a viral vector, and expanded in a perfusion bioreactor. The lentiviral vector manufacturing process starts with cell expansion followed by viral production in a perfusion bioreactor. The broth is clarified by depth filtration and the product is purified by ultrafiltrationdiafiltration and chromatography. This example includes two SuperPro files, one modeling the manufacturing of cell therapy products and the other modeling the manufacturing of viral vectors. |
| Insulin | This example analyzes the production of biosynthetic human insulin (BHI) using recombinant E. coli, which was the first product of the modern biotechnology. The technology was developed by Genentech and commercialized by Eli Lilly in the 1980s. The insulin precursor forms inclusion bodies intracellularly. The inclusion bodies are released through homogenization and partially purified with centrifugation. Next, they undergo solubilization, refolding, chemical transformation and purification with multiple chromatography steps and intermediate membrane filtration. |
| MAB | This example analyzes the production of a therapeutic monoclonal antibody using animal cell culture. It is recommended to users of SuperPro that wish to model and evaluate biopharmaceuticals processes. Its ReadMe file explains several advanced modeling concepts, such as equipment operating in staggered mode for cycle time reduction, multi-cycling chromatography columns, equipment sharing among procedures, backwards scheduling of buffer prep and holding activities, in-line dilution of buffers, buffer losses during transfers, use of transfer panels and delivery lines, etc. Two videos are available for this example on the videos page of our website. |
| Penicillin | This example analyzes the production of penicillin, which was one of the first antibiotics produced via fermentation using fungi. The product is recovered using extraction with butyl acetate. The utilized solvent is purified by distillation and re-used in the process. The fermentation section of the process is batch whereas the purification line operates continuously. |
| Streptomycin | This example analyzes the production of Streptomycin via fermentation using Streptomyces griseus. Streptomycin is a broad-spectrum antibiotic useful in combating infections caused by both gram-negative and gram-positive bacteria that are resistant to penicillin. The product is purified with ion exchange, concentrated by evaporation, crystallized with acetone, and the crystals are centrifuged, washed and freeze-dried. The process analyzed generates around 900 metric tons of purified product per year. |
| Pharma Tablet | This example analyzes the production of pharmaceutical tablets. The process involves mixing of the active pharmaceutical ingredient (API) with various excipients, nano-milling of the suspension, followed by drying/granulation, tablet formation, and coating. |
| Single-Use vs Stainless Steel | This examples compares the use of disposables (a.k.a., single-use) units with traditional stainless-steel equipment for production of therapeutic monoclonal antibodies. It is recommended to users of SuperPro that wish to model and evaluate biopharmaceuticals processes that utilize single-use system. Its ReadMe file provides detailed information on the use of disposables, addition of new items to the Consumables databank, procedure switching (easy replacement of stainless-steel with disposable units), etc. |
| SynPharm | This example analyzes the production of an active pharmaceutical intermediate (small molecule API) which is formed by condensation of quinaldine and hydroquinone. Several reaction and separation steps are required to synthesize and purify the product. It is recommended to users of SuperPro that wish to model and evaluate fine chemical and related processes. Its first ReadMe file explains several modeling concepts, such as equipment sharing among procedures, cycle time bottleneck analysis, process scale up, etc. Its second ReadMe file elaborates on the role of the SuperPro databanks for facilitating and standardizing cost analysis and process technology transfer. |
| Vial (Fill-Finish) | This example analyzes a fill-finish process that manufactures 5 mL lyophilized vials containing a therapeutic protein. The process involves thawing of the frozen product protein solution, preparation of the fill buffer, sterile filtration of the solution, and filling into vials. Then lyophilization is carried out. Finally the vials are inspected before release for packaging and distribution. The cycle time of the process is reduced by utilizing four lyophilizers operating in staggered mode. |
| Hyaluronic Acid | This example describes the microbial production of Hyaluronic Acid. Hyaluronic Acid is a highly viscous and hygroscopic polysaccharide that has numerous medical and cosmetic applications. In this example, hyaluronic acid is produced by fed-batch fermentation, recovered by centrifugation, and purified by ultrafiltration, activated carbon treatment and isopropanol precipitation. This example is recommended to users interested in the production of medium-to-high value bioproducts, such as cosmetic ingredients. |
| Aspirin | This example analyzes the industrial production of acetylsalicylic acid, more commonly known as Aspirin, through the esterification of salicylic acid with acetic anhydride in the presence of phosphoric acid, which acts as a catalyst. The product is recovered and purified through recrystallization, centrifugation and drying. The solvents used in the process are recovered by distillation and recycled back into the process. Two plant scales were modeled and analyzed, corresponding to annual production of 2,400 and 6,500 metric tons of purified aspirin crystals. |
| Ibuprofen | Ibuprofen is an over-the-counter, non-steroidal anti-inflammatory drug which can be used as painkiller and to treat inflammation and fever. Ibuprofen was historically produced using the Boots process in batch mode. This example describes the production of Ibuprofen using a Green Synthesis process in continuous mode. The process involves Friedel-Crafts Acylation, Hydrogenation, Carbonylation, Crystallization and Drying of the Ibuprofen API. The simulated process has an annual production capacity of 5000 metric tons of purified API, which represents 10% of the world demand. |
Nutraceuticals Folder
| Example Name | Example Description |
|---|---|
| Collagen | This SuperPro Designer example analyzes the extraction of Collagen Protein from Chicken Feet. Collagen is the main structural protein present in animal connective tissues such as cartilage, bones, tendons, ligaments, and skin. Collagen has found applications in food supplements, cosmetics, biomedicals, pharmaceuticals, leather manufacturing, etc. The manufacturing plant analyzed in this example processes 2000 kg/h of chicken feet and generates 190 kg/h of collagen with a moisture content of 10%. |
| Inulin | This example analyzes the large-scale extraction of inulin from chicory roots. Inulin is a polysaccharide that occurs naturally in plants. It is composed of fructose molecules joined with a single glucose terminal unit. Inulin exhibits a prebiotic effect in humans promoting digestive wellness and overall health. The manufacturing plant analyzed in this example processes 15,000 kg/h of chicory roots and generates 2,450 kg/h of purified inulin with a moisture content of 5%. |
| Lactoferrin | This example analyzes the production of lactoferrin via the fermentation of genetically engineered yeast. Lactoferrin, a glycoprotein derived from milk, is pivotal in iron metabolism, immune function, and digestive health. It is widely used in high-end baby formulas, dietary supplements, and functional foods. Two scenarios are modeled and evaluated that differ in the downstream section. In scenario 'a', biomass is first removed using centrifugation and crossflow microfiltration. Subsequently, the protein undergoes partial purification and concentration through ultrafiltration/diafiltration (UF/DF) and is then spray dried. Scenario 'b' follows a similar initial step for biomass removal but involves a more intensive purification process using cation-exchange chromatography. Following purification, the protein is desalted and concentrated via UF/DF before being spray dried. The final product from scenario 'b' achieves a higher purity level, making it particularly suitable for inclusion in premium baby formulas. The facility analyzed in this example has the capacity to produce 250 metric tons of lactoferrin annually. |
| Omega-3 Oils | This example analyzes the industrial production of omega-3 oils via microalgal fermentation. Omega-3 oils are polyunsaturated fatty acids (PUFAs) that have been shown to support improved brain health and reduced risk for heart disease. These oils are primarily found in the fat of fish, such as salmon, cod, sardines, mackerel, etc. Some microalgae are rich sources of such oils and can be produced commercially in bioreactors. The manufacturing plant analyzed in this example utilizes microalgae fermentation and produces around 380 kg/h of purified omega-3 oils. Two scenarios are modeled and evaluated, one using hexane for product extraction and another using supercritical CO2. |
| Probiotics | Probiotics are “live microorganisms that, when administered in adequate amounts, confer a health benefit on the host”. They include lactic acid bacteria, bifidobacteria, as well as species from other genera such as Bacillus and Saccharomyces. Probiotics are found in food, beverages, and dietary supplements, with common examples being kefir, yogurt, sauerkraut, and kimchi. This SuperPro Designer example analyzes a probiotics production process that generates 330 kg/batch (or 110 MT/year) of bacterial probiotics (in freeze dried form), which corresponds to 54.3 MT/year of highly viable probiotic cells (on a dry cell mass basis). A plant of this scale requires a capital investment (CAPEX) of around $38 million. |
| Vitamin B12 | This example analyzes the production of Vitamin B12 via fermentation. Cobalamin, the product precursor formed in the cells, is intracellular. The cells are harvested by centrifugation and then lysed with the addition of sodium cyanide and heat. This treatment also converts cobalamin into Vitamin B12. Cell debris is removed by centrifugation and membrane filtration. The product solution is purified with three chromatography column steps, concentrated via evaporation, and crystallized with the addition of acetone, which acts as an antisolvent. A Nutsche filter is used to collect and dry the product crystals. The analyzed plant produces 18,840 kg of purified Vitamin B12 crystals per year. |
Bio-Materials Folder
| Example Name | Example Description |
|---|---|
| B-Galactosidase | This example analyzes the production of ß-galactosidase (b-Gal) by a genetically-engineered strain of E. coli. This model is recommended to users interested in the production of high-value enzymes and bioproducts in general. Its Readme file explains how to use Resource Tracking features to design a water system; how to use Storage Units to represent waste tanks; and how to include formulation and packaging steps in the process. |
| BDO (2,3-butanediol) | This example analyzes the production of 2,3-butanediol (BDO) from sugarcane bagasse, a byproduct of the sugar industry. BDO serves as a versatile platform chemical for producing various chemicals, fuel additives and synthetic rubber. In this process, sugarcane bagasse is hydrolyzed to release sugars, which are then fermented to produce BDO. Following fermentation, the cell mass is separated from the broth, and the BDO is extracted using oleyl alcohol, followed by purification through distillation. The analyzed plant processes approximately 17.6 metric tons (MT) of sugarcane bagasse per hour, producing 20,000 MT of purified BDO annually. The results of the analysis include detailed material and energy balances, equipment sizing, CAPEX / OPEX estimation and profitability analysis. |
| Bio-Aromatics | This SuperPro Designer example analyzes the production of Bio-Aromatics via fermentation. It is a case study on the production of p-Hydroxybenzoic Acid (pHBA) using a strain of Corynebacterium glutamicum. The results include material and energy balances, process scheduling, equipment sizing, capital, and operating cost estimation. |
| Bio-Polymers | This example analyzes the production of polyhydroxyalkanoates (PHAs), which are biodegradable bioplastics that have the potential to replace traditional plastics in various packaging applications, disposable goods, electronic accessories, etc. The bioconversion process utilizes bacteria Cupriavidus necator in 300 m3 fermentors, operating in fed-batch mode, using soybean oil as the main carbon source. After fermentation, the intracellular PHA granules are released by cell disruption and purified with a surfactant / enzyme treatment. The plant analyzed in this example produces 8,300 metric tons of PHAs per year. |
| Citric Acid | This example analyzes the production of citric acid by filamentous fungi. Citric acid is widely used in the food and beverage industries to preserve and enhance flavor. The fermentation section of the process operates in batch model and the downstream in continuous mode. The ReadMe file explains how to model continuous steps in a batch process using independently cycling units. This example is recommended to users interested in the production of commodity bio-chemicals. |
| Farnesene | This example models the production of ß-farnesene (a terpene) by a metabolically engineered yeast growing on glucose. It is recommended to users interested in the production of commodity bio-chemicals. Its Readme file explains how SuperPro handles Physical State calculations and how to customize them; how to employ user-defined equipment cost models; and how to use equipment in Stagger Mode to reduce the process cycle time. |
| Industrial Enzymes | This example analyzes the microbial production of industrial enzymes. The upstream section of the process operates in batch model utilizing multiple seed and production fermentors in staggered mode. The downstream section operates mainly continuously. The Readme file explains various advanced modeling concepts, including the recommended way of recycling water in cascaded membrane filtration systems. |
| Itaconic Acid | This example analyzes the production of itaconic acid, a promising bio-chemical that may replace acrylic acid and other oil-based chemicals in various applications. Itaconic acid is produced by filamentous fungi. The Readme file explains how to track intracellular water and distinguish dry cell weight from wet cell mass. It also explains how to utilize a Flow-Adjustment procedure to implement a robust system of water recycling. |
| Lactic Acid from Cellulosic Biomass | This example analyzes the production of lactic acid from corn stover, a lignocellulosic raw material. Corn stover undergoes thermal and enzymatic hydrolysis to generate fermentable sugars which are converted into lactic acid via fermentation. The product is purified with ion exchange and activated carbon columns, then concentrated by evaporation and distilled. The process analyzed in this example generates 70,000 metric tons of lactic acid per year. |
| Levulinic Acid from Cellulosic Biomass | This example analyzes the production of levulinic acid from lignocellulosic biomass (corn stover in this case), based on a variation of the Biofine process that has been commercialized by GF Biochemicals in Italy. Biomass hydrolysis and levulinic acid formation take place in the same reactors. Formic acid, furfural and humins are co-produced in the process. The products are separated and purified in the downstream section by a series of distillation columns operating at different pressures and temperatures. The manufacturing plant analyzed in this example processes 15 metric tons (MT) of corn stover per hour and generates 23,000 MT/year of levulinic acid, 11,000 MT/year of formic acid and 8,400 MT/year of furfural. |
| Lysine | This example models the industrial production of lysine. Lysine is an essential amino acid for humans and animals that has a large global market as a supplement for animal feed. The production process is based on the fermentation of Corynebacterium glutamicum. Its Readme file explains several advanced modeling concepts, such as how to model batch sterilization in SuperPro; how to employ user-defined equipment cost models; how to model Simulated Moving Bed (SMB) chromatography, etc. |
| Microalgal (Microalgae) Biorefinery | This example analyzes a Microalgal Biorefinery. Microalgae are grown in open solar ponds, utilizing the CO2 of the exhaust of a Combined Heat and Power (CHP) gas turbine. After cell harvesting and disruption, heptane is used to extract the non-polar components from the homogenized slurry. The non-polar components in the organic phase are separated via membrane filtration to produce beta-carotene, the main product of the biorefinery, and free fatty acids. The aqueous phase is processed to produce polar lipids, glycerol, and proteins. Ethanol is used to precipitate part of the proteins, and acetone to precipitate the remaining proteins and carbohydrates. All three solvents (heptane, ethanol, and acetone) are recovered and reused in the process. |
| PDO (1,3-propanediol) | This example analyzes the production of 1,3-propanediol (PDO) by a recombinant E. coli strain. PDO is a small organic molecule that can be utilized in a variety of applications, including the synthesis of polyesters, polyurethanes and polyethers. The fermentation section operates in batch mode and the downstream in continuous mode. This example is recommended to users interested in the production of commodity bio-chemicals. |
| Rhamnolipids | This SuperPro Designer example analyzes the production of Rhamnolipids (Biosurfactants) via fermentation. Biosurfactants produced by microorganisms, such as rhamnolipids, are an important alternative to synthetic surfactants because they are manufactured by utilizing renewable raw materials with a lower carbon footprint. The product is purified using extraction with ethyl acetate which is recovered and recycled in the process. The manufacturing plant analyzed in this example produces around 8,100 metric tons of rhamnolipids per year, requires a total CAPEX of around $95 million and annual operating expenditures of around $50 million. |
| Sophorolipids | This SuperPro Designer example analyzes the production of Sophorolipids via fermentation using a yeast-type of microorganism. Sophorolipids are biosurfactant molecules like rhamnolipids. The product is recovered using phase separation, concentrated by evaporation and spray dried. The manufacturing plant analyzed in this example produces around 15,800 metric tons of sophorolipids per year, requires a total CAPEX of around $91 million and annual operating expenditures of around $58 million. |
| Succinic Acid | This model analyzes the production of succinic acid via bacterial fermentation using glucose syrup 95.5% as carbon source. A train of three seed fermenters inoculate the main production fermenters. The fermentation broth is harvested by centrifugation and passed through ultrafiltration for polishing. The product is purified using ion exchange and activated carbon columns. The product is then concentrated by evaporation and crystallized. The crystalline succinic acid is centrifuged and dried. Part of the mother liquor is recycled back to the evaporator. Part of the water demand of the plant is covered via a water recycle loop. The analyzed plant utilizes 8 production fermenters each having a vessel volume of 355 m3 and generates 18,000 metric tons of crystalline succinic acid per year. |
| Vanillin from Lignin | This example analyzes the industrial production of vanillin from lignin. Vanillin is one of the most prominent flavoring agents and its sustainable production is of high interest to the food processing industry. Lignin is introduced to the facility in an aqueous alkaline solution received from the pulp and paper industry and is oxidized to produce vanillin and other phenolic compounds. Product purification involves several processing steps, including liquid-liquid extraction, distillation, crystallization, centrifugation and drying. The results of the analysis include material and energy balances, equipment sizing, capital, and operating cost estimation. In addition, sensitivity analysis was performed to investigate the impact of the economy of scale. |
| Xantham Gum | This example analyzes the production of xanthan gum. Xanthan gum is a polysaccharide with thickening and stabilizing properties that is widely used in the food, healthcare, and oil industries. In this example, the production process is based on the fed-batch fermentation of Xanthomonas bacteria. Isopropanol is utilized for the precipitation and recovery of the product. The utilized isopropanol is purified with distillation and recycled in pull-mode (the concept is explained in the ReadMe file). The process includes virtual Energy Recovery which is explained in the ReadMe file. |
| Yeast Extract | This example analyzes the production of yeast extract, which is used as a food ingredient and as a substrate in the fermentation industries. The evaluated facility produces 7300 metric tons of powder yeast extract per year. The upstream section of the process operates in batch model utilizing multiple seed and production fermentors in staggered mode. The downstream section operates continuously. |
Bio-Fuels Folder
| Example Name | Example Description |
|---|---|
| Algal Oil | This example analyzes the production and purification of a triglyceride of palmitic acid (TAG) using microalgae grown in raceway ponds. The flue gas of a power plant is the source of carbon. TAG can be used to produce fuels and chemicals in a sustainable manner. The process includes a co-generation unit that supplies steam and electricity to the process. Anaerobic digestion of waste supplies with biogas the co-generation unit. |
| Biodiesel | This example analyzes the production of biodiesel from vegetable oils. It is recommended to users interested in biofuels and biorefineries. The Readme file explains how to take advantage of the virtual Energy Recovery capability of SuperPro. |
| Cellulosic Ethanol | This example analyzes the production of ethanol from corn stover. It can be readily modified to represent the conversion of other types of cellulosic biomass, such as sugarcane bagasse, wheat straw, etc. The flowsheet comprises biomass pretreatment, enzymatic hydrolysis, yeast fermentation, distillation and cogeneration. This example is recommended to users interested in biofuels and biorefineries. |
| Cellulosic Isobutanol | This example analyzes the production of isobutanol from corn stover. Isobutanol can be used as a solvent or as a biofuel. The model comprises biomass pretreatment, enzymatic hydrolysis, bacterial fermentation, purification and cogeneration. It is recommended to users interested in biofuels and biorefineries. The Readme file explains advanced concepts related to the rigorous modeling of vapor-liquid equilibria (VLE) and distillation columns. |
| Hydrogen (Bio and Electrolytic) | This example analyzes the production of green hydrogen via bioconversion and water electrolysis. The bioconversion process utilizes 18 metric tons (MT) per hour of wheat straw as feedstock which is converted into fermentable sugars via thermochemical and enzymatic hydrolysis. Hydrogen is produced using a combination of sequential dark and photo fermentation and the product is purified using pressure swing adsorption. The process generates 1.1 MT/hour of purified hydrogen. The electrolytic process starts with 10 MT/hour of city water which is converted into ultrapure water and then it is electrolyzed to produce 1.1 MT/hour of purified hydrogen. This example also includes a model for hydrogen liquefaction. The results of the analysis for all three processes include material and energy balances, equipment sizing, capital, and operating cost estimation. The results indicate that significant government subsidies are necessary for the financial viability of such investments considering the current technologies and market dynamics. |
| Wood Liquefaction | This example simulates a wood hydrothermal liquefaction (HTL) plant that generates renewable gasoline and diesel. HTL is a thermochemical treatment at high temperature (280-370 °C) and pressure (10-25 MPa) regimes to liquefy biomass feedstocks. The analyzed HTL plant processes 50 metric tons per hour (MT/h) of wood biomass and generates 5.98 MT/h of gasoline, 2.65 MT/h of diesel and 4.03 MT/h of char. The results of the analysis include material and energy balances, equipment sizing, capital, and operating cost estimation. |
| Wood Pyrolysis | This SuperPro Designer example analyzes a Wood Biomass Pyrolysis facility that processes 30 metric tons per hour of wood biomass and generates 3300 kg/h of biochar and around 10000 kg/h of two types of bio -oil. The results of the analysis include material and energy balances, equipment sizing, capital, and operating cost estimation. The estimated capital investment (CAPEX) for such a plant is around $54 million. |
Food Processing Folder
| Example Name | Example Description |
|---|---|
| Beat Sugar | This example analyzes a Sugar Beets Plant that produces sucrose, molasses, dry pulp for animal feed and lime cake. Its co-generation unit supplies utilities to the plant and sells electricity to the grid. The results of the analysis include material and energy balances, equipment sizing, capital, and operating cost estimation. |
| Brewery | This example analyzes a generic brewery that produces 126,000 L of beer per day (5% alcohol by volume). The results include material and energy balances, equipment sizing, capital, and operating cost estimation, process scheduling and cycle time analysis. Heat integration opportunities are analyzed as well. A video is available for this example on the videos page of our website. |
| Cultured (Cultivated) Meat | This example analyzes the manufacturing of cultured (cultivated) meat. The process starts with the proliferation of muscle stem cells over multiple culture steps, using bioreactors with microcarriers. After that, the cells are differentiated into muscle fibers by changing the culture medium. Subsequently, the cell suspension is sent to a crossflow filtration system for concentration and diafiltration, and then transferred to a screw press for dewatering. Lastly, the meat product is packaged and refrigerated. Approximately 3,000 MT of cultured meat is produced per year. |
| Carrageenan | This example analyzes the production of carrageenan from seaweed via extraction. Isopropanol is utilized for the precipitation and recovery of the product. The utilized isopropanol is purified with distillation and recycled in pull-mode (the concept is explained in the ReadMe file). The process includes virtual Energy Recovery which is explained in the ReadMe file. A video is available for this example on the videos page of our website. |
| Cassava Refinery | This example analyzes an integrated cassava refinery that produces tapioca starch, β-cyclodextrins, and animal feed. The ReadMe file explains how to model enzymatic reactions, a direct fired dryer for drying the animal feed, virtual energy recovery and recycling of water in pull-mode. |
| Cheese / Milk Processing | This example analyzes an integrated milk processing plant that produces cheese, butter, whey protein concentrate (WPC), and food-grade ethanol. The plant processes 2,000 metric tons (MT) of milk per day and produces 214 MT of cheese, 119 MT of butter, 15 MT of WPC, and 35 MT of 95% (by mass) ethanol. The results of the analysis include material and energy balances, equipment sizing, capital, and operating cost estimation. |
| Skim Milk Powder | This example analyses a milk processing plant that produces cream and skim milk powder (SMP). It processes 100 metric tons (MT) of milk per batch with a recipe cycle time of 1 day (one batch is initiated daily). The plant operates for 11 months per year producing 3000 MT of SMP and 3500 MT of cream per year. The CAPEX of the project is around $54 million and the OPEX is $29 million/year. Assuming a milk purchase price of $0.57/kg and a selling price of SMP for $4.5/kg and cream for $7.6/kg, the payback time of the investment is estimated to be around 4.2 years. |
| Cocoa Processing | This example analyzes a cocoa beans processing plant that produces various categories of cocoa powders (plain, alkalized, chocolate flavored) and cocoa butter. The latter is used to produce various types of chocolate (dark, milk, white). The results of the analysis include material and energy balances, equipment sizing, capital, and operating cost estimation. |
| Corn Refinery | This example analyzes an integrated wet milling corn refinery, which fractionates corn to corn germ, corn gluten feed (including the corn steep liquor), corn gluten meal, and natural starch. The integrated refinery then uses part of the natural starch to produce glucose and fructose syrups (namely 95% glucose, and High Fructose Corn Syrup 42%). Several advanced modelling concepts are explained in the ReadMe file, such as modeling of batch (cyclical) steps in continuous processes, explicit and virtual energy integration, recycling in pull mode, user defined equipment cost models, material storage units, etc. A video is available for this example on the videos page of our website. |
| Dextrose | The Dextrose example utilizes 95% glucose syrup (the origin of which could be corn, potato or tapioca starch) to produce the crystalline products dextrose anhydrous and dextrose monohydrate (in 2 cuts), as well as the hydrogenated 95% sorbitol spray dried. Moreover the by product of the dextrose monohydrate is also hydrogenated to produce non-crystalline sorbitol. This integrated flowsheet can be considered as the continuation of the corn refinery example |
| Erythritol | This example analyzes the production of erythritol through fermentation, utilizing glycerol as a carbon source. Erythritol, a four-carbon sugar alcohol, serves as a natural sweetener and is an alternative to sugar in the food industry. The process commences with fermentation, followed by the removal of biomass using centrifugal separators. The resulting clarified broth undergoes purification through a series of steps including ion exchange, activated carbon adsorption, multi-effect evaporation, and simulated moving bed chromatography. Following purification, erythritol is crystallized in two sequential reactors. The crystals are recovered and washed in a basket centrifuge, then dried in a rotary dryer to yield the final crystalline product. Annually, this process produces 10,405 metric tons of crystalline erythritol. |
| GasFermentSCP (Single-Cell Protein via Gas Fermentation) | This example focuses on the analysis of a single-cell protein (SCP) production process using Basic Oxygen Furnace (BOF) gas as the primary feedstock. The analyzed plant has the capacity to produce 20,000 metric tons of SCP annually. The carbon monoxide of BOF serves as the carbon source that supports the growth of acetogenic bacteria (M. thermoacetica) and the production of acetate in airlift fermentors that operate anaerobically. The broth from the airlift fermentors, containing the acetate, is then directed to aerobic fermentors, where another bacterium (C. necator) is cultivated. The broth from the aerobic fermentors undergoes microfiltration, is heat-inactivated, and then concentrated using a multi-effect evaporator before being spray-dried to generate the Single Cell Protein product. The process includes extensive recycling of water and ammonia and treatment of wastewater via anaerobic digestion and activated sludge. |
| Ice Cream Manufacturing | This example analyzes an ice cream manufacturing facility that operates in batch mode with a cycle time of 12 hours (a new batch is initiated every 12 hours). It produces 7,200 metric tons of vanilla ice cream per year, 60% of which is packaged in 1 kg containers and the rest is formulated into chocolate covered sticks. The estimated capital investment for such a plant is around $20 million. |
| Insect (Cricket) Protein | This example analyzes the large-scale production of cricket protein powder. Crickets provide a complete protein source, containing all nine essential amino acids critical for human health. Additionally, they are rich in iron, B vitamins, zinc, and calcium. The analyzed plant processes 5 metric tons (MT) of crickets per hour, translating to 39,200 MT/year. This results in the production of 10,300 MT/year of concentrated cricket protein powder and 2,245 MT/year of cricket fat. Extraction of fats with ethanol facilitates protein defatting. The final product contains 82% protein on a dry basis. |
| Mannitol | The Mannitol example utilizes 95% glucose syrup (the origin of which could be corn, potato or tapioca starch) to produce crystalline mannitol. First, glucose is converted into mannose. Mannose is separated from glucose using a Simulated Moving Bed (SMB) chromatography column. Hydrogenation of mannose yields mannitol. The product is purified using ion exchangers, evaporators, crystallizers and centrifuges. |
| Modified Starches | This example analyzes the production of modified starches (hydroxyl-propylated starches) from natural starch (the origin of which could be corn, potato or tapioca starch). The process flowsheet includes batch reactors, stripper and scrubber columns for volatile chemicals removal, as well as hydrocyclones and other typical starch processing units. |
| Monosodium Glutamate (MSG) | This example analyzes the production of monosodium glutamate (MSG) via fermentation using Corynebacterium glutamicum. MSG is used as a flavor enhancing ingredient in Japan, China and other countries. The fermentation section operates in batch mode utilizing multiple fermentors in staggered mode. The product is recovered and purified continuously using a combination of centrifugal separators, ion exchange and activated carbon columns, a neutralizer, an evaporator / crystallizer, a rotary vacuum filter and a rotary dryer. |
| Mycoprotein | This example analyzes the industrial production via fermentation of meat-like fungi protein (mycoprotein). The process is based on the submerged culture of a filamentous fungus in a 200 m^3 airlift fermentor. The fermentation operates in a semi-continuous manner, using a defined medium and ammonia. The resulting broth is heated with live steam for inactivation of the microorganism and reduction of the RNA content. After that, the biomass is concentrated by filtration, mixed with egg albumen, and texturized through a series of mechanical and thermal steps. The analyzed plant produces a total of 8,000 metric tons (MT) of chicken-like mycoprotein pieces per year. |
| Orange Juice (OJ) Powder | This example analyzes a process for producing dehydrated orange juice powder. The process consists of the following steps: fruit preparation (washing, sorting, and sizing), concentrated juice production (extraction, finishing, concentration, and pasteurization), formation of powder and packaging. Additional byproducts include peel oil, which is sold to cosmetics manufacturers, and animal feed. |
| Potato Refinery | This example analyzes an integrated potato refinery that produces potato starch, proteins, protamylase and fibers. The process flowsheet includes multiple wash steps, reactions, virtual energy recovery and extensive water recycling and reuse. |
| Sorbitol | The sorbitol example utilizes 95% glucose syrup (the origin of which could be corn, potato or tapioca starch) to produce 95% sorbitol spray dried. The process flowsheet includes multiple reactors, ion exchangers, activated carbon columns, evaporators, a spray dryer, and extensive recycling of water in pull mode. |
| Soybean Refinery | This example analyzes a soybean refinery, which includes two SuperPro models (Case A and B). Case A models a typical soybean crush plant which produces soybean oil, soybean meal, lecithin and hulls. The hexane used for the crude oil extraction is separated from the miscella and the marc and recycled back to the process. The crude oil is refined via degumming, neutralization, bleaching and deodorization. In Case B, part of the soybean meal undergoes additional processing to co-produce Soy Protein Concentrate (SPC) and Soy Protein Isolate (SPI) which contain 65% and 92% protein on a dry basis, respectively. |
| Sunflower Oil | This example analyzes a Sunflower Seed Crush Plant that produces sunflower oil, lecithin, soap stock and cake for animal feed. Its co-generation unit satisfies the utility needs of the process and sells electricity to the grid. The ReadMe file explains how to model steam boilers and turbines, neutralizers, condensers, evaporators, reactors, strippers, dryers, etc. |
| Xylitol | This example analyzes the industrial production of xylitol via fermentation using Brewer's Spent Grain (BSG) as a feedstock. The process begins with the pretreatment of BSG to release xylose and arabinose. The fermentation step employs yeast (Debaryomyces hansenii), which converts xylose to xylitol and arabinose to arabitol. The downstream section begins with cell mass removal, followed by product purification using activated carbon and ion-exchange columns. Subsequently, the product solution is concentrated in a multi-effect evaporator before undergoing further purification in a simulated moving-bed chromatography column, which separates arabitol from xylitol. The xylitol-rich extract is concentrated and then crystallized in two continuous crystallizers. The crystals are separated and washed using basket centrifuges and then dried in a rotary drum dryer. The analyzed plant produces a total of 14,200 metric tons (MT) of crystalline xylitol annually. |
Metallurgy Folder
| Example Name | Example Description |
|---|---|
| Battery Cathode Material | This example analyzes a batch process producing nickel-rich cathode material for lithium-ion batteries, namely NMC 811. The cathode material is produced from older generation cathode scraps (NMC 111) by means of hydrometallurgical and hydrothermal processing. The ReadMe file of this example explains several modeling concepts, such as equipment operating in staggered mode for cycle time reduction and equipment sharing among procedures. |
| Lithium-Ion Battery Recycling | This example analyzes a batch physico-hydrometallurgical process for recycling of end-of life lithium-ion batteries. The separation and recovery of ferrous and non-ferrous metal fractions as well as manganese sulfate, cobalt sulfate, nickel and lithium carbonates is accomplished by means of physical sorting, leaching, precipitation, solvent extraction and crystallization. Staggered equipment is employed for the cycle time bottleneck steps to reduce the process cycle time and increase the overall process throughput. |
| Lithium Extraction | This example analyzes a continuous hydrometallurgical process for the extraction of lithium from spodumene ore and generation of battery-grade lithium carbonate. The flowsheet features decrepitation, sulfatation-roasting, purification by sequential neutralization and evaporation-crystallization. The results of the analysis include material and energy balances, equipment sizing, capital, and operating cost estimation. |
| Rare Earth Elements (REE) | This example analyzes a continuous process for the extraction, separation, purification and recovery of light rare earth oxides from a fluorocarbonate-rich ore. The process features mineral processing by comminution, magnetic separation and flotation prior to hydrometallurgical operations such as leaching, precipitation and solvent extraction. The process includes extensive water recycling in pull-mode. |
| Cu-Ni Matte Leaching | This example analyzes a hydrometallurgical process for the valorization of copper-nickel matte. Nickel is extracted by pressure oxidation-metathesis with the accumulation of the reduced copper minerals in the leaching residue. The readme file of this example provides a techno-economic assessment of the process and explains the concept of recycling in pull-mode. |
| Copper and Gold Bioleaching | This example analyzes a bio-hydrometallurgical process for the extraction, purification and recovery of copper and gold from a refractory concentrate. The process features preparation and bioleaching of the concentrate, solvent extraction, and electrowinning of copper as well as gold extraction by thiosulfate-ammonia leaching, ion-exchange and electrowinning of gold. The results include detailed material and energy balances, equipment sizing, capital, and operating cost estimation. |
| Zircon Processing | This example analyzes a continuous hydrometallurgical process for the extraction, separation and recovery of zirconium, uranium and hafnium from zircon sand. The process features alkali fusion, leaching, precipitation and solvent extraction in counter-current mode for the separation and recovery of the three valuable metals. |
| Printed Circuit Boards (PCBs) Recycling | This example analyzes a hydrometallurgical process for recycling of printed circuit boards (PCBs), which account for 3-6% of the total amount of waste of electric and electronic equipment (WEEE). The process features mechanical pretreatment and multiple hydrometallurgical sections to separate copper, aluminum, zinc, silver and gold among other materials. Copper is recovered by electrowinning upon primary leaching in sulfuric acid / hydrogen peroxide and aluminum precipitation. Silver is recovered by electrowinning after leaching the primary leach residue in nitric acid. Gold is extracted from the final residue using hydrochloric acid / hydrogen peroxide and recovered via reduction with ferrous chloride. |
| Solar Photovoltaic Panels Recycling | This example analyzes a physico-chemical process for recycling of end-of-life solar photovoltaic panels. The process enables the separation and recovery of aluminum frames, glass, metal contacts, silicon, and silver by means of mechanical, chemical, and hydrometallurgical operations. |
| Aluminum | This SuperPro example analyzes a metallurgical process for production of aluminum (aluminium) from bauxite ore. The designed flowsheet is based on the Bayer and Hall-Heroult processes. The overall process runs in continuous mode treating 475,000 metric tons (MT) of bauxite ore and producing 62,000 MT of aluminum per year. It generates revenues of $125 million per year against annual operating costs of $110 million. The results of the analysis include detailed material and energy balances, equipment sizing, capital, and operating cost estimation. |
Inorganic Materials Folder
| Example Name | Example Description |
|---|---|
| Boric Acid | This example analyzes a continuous hydrometallurgical process producing boric acid from colemanite concentrate. The process features leaching of the concentrate with sulfuric acid, purification of the extracted boric acid by crystallization and re-dissolution, and a final crystallization to recover purified boric acid crystals. The results of the analysis include detailed material and energy balances, equipment sizing, capital, and operating cost estimation. The process analyzed in this example generates 88,000 metric tons of purified boric acid per year. |
| Cement Manufacturing | This example simulates a cement manufacturing plant where cement clinker is produced by mixing clay and limestone. First, clay and limestone are crushed, ground and mixed in specific proportions. The homogenized mixture is then fed to the kiln system where it is preheated in cyclone preheaters, precalcined, converted into clinker in a kiln and cooled down in a grate cooler. The produced clinker is then mixed with gypsum and ground once more to form the cement. The plant processes 65 MT/h of clay, 260 MT/h of limestone and 12.5 MT/h of gypsum to produce 220 MT/h (1.75 million MT/year) of cement. |
Waste Valorization Folder
| Example Name | Example Description |
|---|---|
| Mango Kernel Refinery | This example analyzes the extraction of valuable materials, such as Mango Oil, Protein, Fiber and Starch from Mango Kernels. The process features a co-generation unit and purification / recycling of hexane used for the extraction of mango oil. The results of the analysis include detailed material and energy balances, equipment sizing, capital and operating cost estimation. |
| Pectin from Citrus Peels | This example analyzes the production of pectin from orange peels along with co-production of animal feed and vinasse. Isopropanol facilitates the precipitation and purification of pectin. The process includes extensive recycling of water and isopropanol in pull-mode. The ReadMe files explains how to track the composition of streams on a dry-mass basis along with several other modeling concepts. |
| Plastics (LDPE) Gasification and Hydrogen Production | This example analyzes the production of hydrogen through the gasification of Low-Density Polyethylene (LDPE). The process employs 10 metric tons (MT) per hour of LDPE as feedstock, converting it into 1.46 MT/hour of hydrogen. This transformation occurs in a gasifier operating in adiabatic mode, supplemented by a series of compressors, heat exchangers, and flash units. Additionally, two adiabatic plug flow reactors facilitate the water-gas shift reaction, while two pressure swing adsorption (PSA) units recover the generated hydrogen. The off-gas from the PSA units fuels a gas turbine-generator to produce electricity |
| Waste Tire Pyrolysis | This example analyzes a plant that processes 30 metric tons per hour of waste tires through pyrolysis and generates 12430 kg/h of char, 1800 kg/h of light oil and 6500 kg/h of heavy oil. Pyrolysis is treatment at temperatures of around 550 C in a non-oxidizing environment, which converts the rubber raw material into solid char, liquid oil, and gases. The results of the analysis include material and energy balances, equipment sizing, capital, and operating cost estimation. The estimated capital investment (CAPEX) for such a plant is around $27 million. |
Environmental Folder
| Example Name | Example Description |
|---|---|
| Air Pollution Control | This example models a sequence of three units (cyclone, bag house filter and scrubber) for removing solid particles (Dust) and a volatile organic compound (Acetone) from an air stream with a volumetric flowrate of around 12,500 m3/h. |
| GE | This example analyzes an effort to minimize wastewater and hazardous sludge generation at a former polymer manufacturing plant of General Electric. Case (A) represents the original process. Case (B) utilizes VSEP membrane filtration units to treat and recycle the major source of wastewater that does not include hazardous materials. This greatly reduces the amount of hazardous sludge that requires disposal and the demand for fresh water. |
| Incineration | This example explains how to model incinerators in SuperPro Designer. |
| Industrial Wastewater | This example focuses on biological treatment of industrial wastewater. It explains how to model emissions of VOCs from such facilities and how to track the fate of heavy metals that adsorb on sludge. |
| Municipal Wastewater | This example focuses on the modeling and retrofit design of a municipal wastewater treatment plant. Case (A) represents a typical activated sludge plant without any sections for nitrogen removal. Case (B) represents a modified Ludzack-Ettinger process for nitrogen removal using anoxic zones. Case (C) represents a 4-stage Bardenpho process for more effective nitrogen removal |
| Ultrapure Water | This example analyzes a process that produces ultrapure water for a semi-conductor manufacturing facility. The inlet water is purified using a combination of activated carbon filters, anion & cation exchange columns, ultrafiltration and reverse osmosis (RO) membrane filters. In Case (A), the contaminated water undergoes physical treatment and released into the environment. Case (B) utilizes additional RO units to purify and recycle the treated water, reducing by 85% the demand for inlet well water. |
| Food Industry Wastewater | This SuperPro Designer example analyzes a food industry wastewater treatment plant. Anaerobic Digestion is utilized to generate biogas which in turn is burned to generate electricity. The digestate stream undergoes oxidation in a typical activated sludge process. The treated sludge is sold as fertilizer. The clarified water is converted into potable water after undergoing disinfection and membrane filtration. The results include material and energy balances, equipment sizing, capital, and operating cost estimation. |
COM, EPA-MACT Report, and Misc Folders
| Folder Name | Example Description |
|---|---|
| COM | The examples of this folder explain how to drive SuperPro Designer through Excel, C# and other programming tools in order to automate sensitivity analysis, perform mathematical optimization and conduct Monte Carlo simulation. |
| EPA-MACT Report | The examples of this folder explain how to use SuperPro Designer and its Custom Excel Reporting feature to generate an EPA-MACT report for a single batch of a single recipe or an entire multi-product facility over a long-time horizon. |
| Misc | This folder includes several small examples that explain specific modeling concepts, such as modeling of kinetic and equilibrium reactions, gasifiers, fuel cells, heating with live steam, batch distillation, detailed hydrocyclones, pull operations, in-line mixture preparation, visualizing vessel contents, etc. Documentation is provided on the flowsheets of the examples. |