Pilot scale test specification

Autoclave System Test Specification:

Pre-Starting

Please read these instructions thoroughly. This will make sure you obtain full safe use, Keep this instruction manual in a handy place for future reference.

Filling the tank

Make sure all valves are closed
Make sure the power is turned off
Connect the water valve to autoclave
Open the water to fill the tank (amount of water should be between 60-70%)
Close the valve for water filling

Safety precaution

The hot water (121 °c) could suffer of second-degree burns

Autoclave operation method

1-Ensure all sanitary connections

2-Fill the autoclave tank with water

3-Plug the control system to electricity

4-check the control system if it works properly (Check if the valves works by turning them ON and OFF)

5-Operate the heater

6- Wait till the water transforms to steam (T= 121°C / P= 20000 Pa), operate the autoclave valve system to open

7-After finishing, Operate the pipe to open (to decrease the pressure)

System testcases

001: test the resistor of the autoclave

Step	Step Description	Expected Result
Precondition	System is off
Switch on the system	Turn on the heater	The water degree starts to going up to reach 121°c
Switch off the system.	Turn off the heater	The water will remain warm and could last for 5-6h
Postcondition	System is off

002: AUTOCLAVE SYSTEME TEST OF PENICILLIN PRODUCTION

Step	Step Description	Expected Result
Precondition	System is OFF
open/close the valves	open all valves from the control panel and reclosed them after few minutes	Release the air from the system
Switch on the heater	Turn on the heater from the control panel	THE SYSTEM IS heating the water till reach 121°C
Sterilization of the fermenter	Open the autoclave valve (autolave--->Autoclave valve)	The steam is filling the fermenter
Sterilization of the whole system	Open the fermenter valve to sterilize last 2 tanks (autolave--->fermenter--->fermenter valve)	Pressure should reach 2 atm (20000 Pa) and temperature 121 °C
Open the manual discharge valve	Open the discharge valve manually	Pressure should decrease and the steam vent off the system
CLose the valves	close ALL the valves from the control panel and the discharge valve manually	ALL the valves are closed
switching OFF the system	switch off the system	the system is OFF
Postcondition	system is OFF

Aspirin Production System Test Specification:

Pre-Starting

Please read these instructions thoroughly. This will make sure you obtain full safe use, Keep this instruction manual in a handy place for future reference.

Prepare the reactor

Make sure all valves are closed
Make sure the power is turned off
Connect the reactif valve to the reactor
Put the amount needed of the reactifs in the reactor (amount of reactifs: 1013.5g of salicylic acid, 2.5L acetic anhydride and 125ml concentrated H2SO4)
Closed the valve for reactifs filling.

Safety precaution

-The hot water (80 °c) could suffer some burns (tank number 2)

-Concentrated Sulfuric acid causes severe skin burns and eye damage. (Wear protective gloves/protective clothing/eye protection/face protection).

Aspirin Production operation method

1-Ensure all sanitary connections

2-Put the reactifs in the reactor (salicylic acid, acetic anhydride and H2SO4)

3-Plug the control system

4-check the control system if it's works properly

5-Operate the mixer to mix the reactifs in the reactor

6-Operate to add warm water to the mixture

7-Open the valves to reach the filtration system

8-Operate to open the vacuum pump in the filtration system

9-Operate the valves to refiltration the aspirin

7-After finishing, Operate the pipe to close.

System testcases

003: AUTOCLAVE SYSTEME TEST OF ASPIRIN PRODUCTION

Step	Step Description	Expected Result
Precondition	System is off
open/close the valves	open all valves from the control panel and reclosed them after few minutes	The air is Released from the system
Switch ON the heater	Turn on the heater from the control panel	THE SYSTEM IS heating the water till reach 134°C
Sterilization of the reactor (tank 1)	Open the autoclave valve (autolave--->Autoclave valve)	The steam is filling the reactor (tank 1) P= 2 Bar (2000 mBar)/T= 134 °C
Sterilization of the cooler (tank 2)	Open the reactor valve V1 (tank 1) to sterilize the cooler (autolave--->Reactor--->Reactor valve V1)	The steam is filling the reactor (tank 1) and the cooler (tank 2) P= 2 Bar (2000 mBar)/T= 134 °C
Sterilization the tank 3 (HOT WATER TANK)	Open the tank 3 (HOT WATER TANK) valve V6 to sterilize tank 3 (HOT WATER TANK---->HOT WATER TANK valve V6)	The steam is filling the reactor (tank 1), the cooler (tank 2)and the HOT WATER TANK (tank 3) P= 2 Bar (2000 mBar)/T= 134 °C
Sterilization of the crystallizer (tank 4)	Open the tank 2 (cooler) valve V2 to sterilize tank 4 (crystallizer) (crystallizer---->crystallizer valve V2)	The steam is filling the reactor (tank 1), the cooler (tank 2), the HOT WATER TANK (tank 3) and the crystallizer (tank 4) P= 2 Bar (2000 mBar)/T= 134 °C
Sterilization of the vacuum filter (tank 5)	Open the valve V3 to sterilize tank 4 (Crystallizer) to the tank 5 (Filter) (crystallizer---->crystallizer valve V3)	The steam is filling the reactor (tank 1), the cooler (tank 2), the HOT WATER TANK (tank 3), the crystallizer (tank 4) and the vacuum filter (tank 5) P= 2 Bar (2000 mBar)/T= 134 °C
Sterilization of the waste tank (tank 6)	Open the valve V4 tank 5 (Filter) to sterilize tank 6 (Waste) (Filter---->Filter valve V4)	The steam is filling the reactor (tank 1), the cooler (tank 2), the HOT WATER TANK (tank 3), the crystallizer (tank 4), the vacuum filter (tank 5) and the waste tank (tank 6) P= 2 Bar (2000 mBar)/T= 134 °C
Open the manual discharge valve	Open the discharge valve manually	Pressure should decrease and the steam vent off the system
Switch OFF the heater	Turn OFF the heater from the control panel	the heater is OFF
CLose ALL the valves	close ALL the valves from the control panel and the discharge valve manually	ALL the valves are closed
switching OFF the system	switch off the system	the system is OFF
Postcondition	system is OFF

004: ASPIRIN PRIDOUCTION SYSTEME TEST

Step	Step Description	Expected Result
Precondition	System is OFF
TURNING ON the system	Turn ON the control panel	The system is ON
Switch on the mixer 1 (tank 1: Reactor)	Turn on the mixer 1 from the control panel (Reactor--->Mixer ON)	Mixing the reagents to obtain the mixture in the reactor (tank 1)
Open the valve V1 (tank1 : Reactor)	Open the valve V1 to transfer the mixture from tank 1 (reactor) to tank 2 (cooler) (Reactor---->Reactor valve V1)	The mixture is transferred to cooler (tank 2)
Open the valve 6 (tank 3 : HOT WATER)	Open the valve V6 to add water from HOT WATER TANK (tank 3) to the cooler (tank 2) (HOt WATER TANK---->HOT WATER TANK valve V6)	The warm water is in the cooler (tank 2) with the mixture
Open the valve V2 (tank 2: Cooler)	Turn ON the pump 1 Open the valve V2 to transfer the Water from cooler (tank 2) to crystallizer (tank 4) (cooler---->cooler pump 1) (cooler---->cooler valve V2)	The reagents are transferred to the crystallizer (tank 4) and formation of crystals
Switch on the mixer 2 (tank 4 : Crystallizer)	Turn on the mixer from the control panel (Crystallizer--->Mixer ON)	Mixer 2 is ON and start Mixing the reagents in the Crystallizer (tank 4)
Open the valve V3 (tank 4: Crystallizer)	Open the valve V3 to transfer the Water from crystallizer (tank 4) to the filter (tank 5) (crystallizer---->crystallizer valve V3)	The mixture transferred to the filter (tank 5)
Switch on the vacuum pump	Turn on the vacuum pump from the control panel (Filter---->Filter pump ON)	The air is vacuumed in tank 6 (Waste tank)
Open the valve V4 (tank 5 : Filter)	Open the valve V4: 1-the vacuum filtration begin 2-Aspirin crystals are now in the filter (tank 5) (Filter---->Filter valve V5)	The filtrate transferred to the waste tank (tank 6)
Open the valve V7	Open the valve V7 to add 30L warm water from WARM WATER TANK (tank 3) to vacuum filter (tank 5) (WARM WATER TANK---->WARM WATER Valve V7)	Crystals re-dissolved with 30L warm water after 20min in the vacuum filter (tank 5)
Open the valve V5 and pump 2 (tank 5 : Filter)	Open the valve V5 The solution is pumped from tank 5 to tank 4 for the second crystallization (vacuum filter---->vacuum filter Valve V5)	Solution transferred to the crystallizer (tank 4) and start the crystallization
Switch on the vacuum pump for the second filtration	Turn on the vacuum pump from the control panel (Filter---->vacuum pump ON)	The air is partial vacuumed in tank 6
Open the valve V3 and V4	Open the valve V3 and V4: 1-the vacuum filtration begin 2-Aspirin crystals are now in the vacuum filter (tank 5) (1-crystallizer---->crystallizer valve V3) (2-vacuum filter---->vacuum filter valve V4)	The filtrate transferred to the waste tank (tank 6)
switching OFF the system	switch OFF the system	the system is OFF
Postcondition	system is OFF