CFD, Plant Simulation, Mechanistic & Process Modeling

Advanced computer modeling and simulation techniques can provide KBI customers increased process understanding while at the same time minimizing investment in costly experimentation. KBI staff has extensive experience developing and applying computer modeling tools in the biotechnology industry. Our modeling capabilities include mechanistic unit operation modeling (see for example our software around Chromatography modeling), computational fluid dynamics (CFD), process modeling and plant simulation. At KBI, we are passionate about leveraging computational tools to improve process development in the biotechnology industry and integrating modeling and simulation into our process development activities is one of the ways KBI ensures robust and cost-efficient processes.

Modeling and Simulation Service Offerings

  • Development of mechanistic unit operation models
  • Application of mechanistic models for chromatography and ultrafiltration
  • Application of Computational Fluid Dynamics (CFD) to biotechnology unit operations for equipment design or process troubleshooting
  • Perform process modeling to improve process throughput, evaluate facility fit and understand cost of goods
  • Perform plant simulation to optimize new or existing facility capacity
  • Application of modeling to evaluate process or platform improvements
  • Application of modeling to evaluate facility or equipment designs
  • KBI’s Modeling & Simulation Capabilities

      • Mechanistic models leverage scientific and engineering knowledge to develop a mathematical description of the fundamental processes occurring within the unit operation

      • These models typically require some experimentation to define model parameters, after which predictions can be made with respect to unit operation performance over a wide range of operating parameter conditions

      • Mechanistic models can be used for process optimization, evaluating process robustness and to fully characterize performance of the unit operation within a specified operating space

      • Learn more about our Mechanistic Modeling Software Solution

      • Process modeling utilizes mass and energy balances combined with information about the process and production facility to understand process and facility fit

      • Costs for raw materials, capital, labor and disposables are then incorporated to calculate the overall cost of goods

      • Application of process modeling during process development is essential to ensuring a cost effective process

      • Computational fluid dynamics (CFD) is a first principles technique in which the differential equations describing fluid, mass and heat transfer are solved computationally for a fluid contained in a specific geometry

      • CFD can be used to characterize mixing in process vessels, estimate gas mass transfer in bioreactors or understand flow distribution in chromatography columns

      • This technique is most beneficial in situations where taking experimental measurements is very difficult or expensive and a more complete understanding is required for successful process scale-up or transfer

      • Plant simulation combines process and facility information (process sequence, process timing, equipment availability, etc.) into a mathematical framework that enables optimization of facility run rate via constrained optimization techniques

      • Plant simulation is used to understand the impact of process, equipment or operational changes on the maximum run rate of a facility as well as to support finite scheduling in manufacturing

      • Application of plant simulation ensures the process you are developing or the facility you are designing will deliver the capacity target you expect

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