Design analysis for refolding monomeric protein

Renaturation of protein expressed as inclusion bodies within Escherichia coli is a key step in many bioprocesses. Operating conditions for the refolding step dramatically affect the amount of protein product recoverd, and hence profoundly influence the process economics. The first systematic comparison of refolding conducted in batch, fed‐batch and continuous stirred‐tank reactors is provided. Refolding is modeled as kinetic competition between first‐order refolding (equilibrium reaction) and irreversible aggregation (second‐order). Simulations presented allow direct comparison between different flowsheets and refolding schemes using a dimensionless economic objective. As expected from examination of the reaction kinetics, batch operation is the most inefficient mode. For the base process considered, the overall cost of fed‐batch and continuous refolding is virtually identical (less than half than of the batch process). Reactor selection and optimization of refolding using overall economics are demonstrated to be vitally important.