Archived: Secrets of Batch Process Scale-Up

Date: 26 September - 28 September 2017

Location: Madrid, Spain

Tutors: Francis X. McConville

Operating a commercially viable chemical process requires a good chemical synthesis to start with, but is also subject to the interplay of a myriad of important physical phenomena – heat transfer, mass transfer, fluid flow, etc. which are traditionally the realm of the chemical engineer. An understanding of these scale-up phenomena is crucial for the laboratory development of processes that will scale successfully.

This course presents an overview of these issues and examines their impact on process operation in the pilot plant and beyond, including scale-up considerations for route selection, raw material charging, reaction steps, workup, crystallization, product isolation, drying, etc. Common bench techniques for each of these steps are contrasted to the safety and operability criteria for successful pilot plant operation. Numerous examples and case histories are presented, along with tips and techniques for operators and experimenters. Heavy emphasis is placed on process safety.

An underlying goal of the course is improving communication and mutual understanding between development team members of different backgrounds; thus, the course is appropriate for synthetic chemists, process development chemists and process engineers with limited pilot plant experience who wish to learn more about the potential pitfalls of scale-up in process development. The course complements the more chemistry-focused Scientific Update course “Chemical Development and Scale-Up in the Fine Chemical and Pharmaceutical Industries”.

Download Brochure

Course outline

Process Design for Scale-Up
Process development strategies
Importance of engineering in PDs
Scale-Up – An Overview
Role of the Pilot Plant
Overview of scale-up issues
Technology transfer issuesBatch Reactors
Typical plant operations and equipment
Characteristics of batch operationsRaw Materials
Raw material and route selection
Large-scale charging methods and issuesTemperature Control
Large scale temperature control
Heat transfer in batch reactors
Controlling exothermic reactionsFollowing Reaction Progress
Reaction endpoint determination
Sampling methods / issues
On-line analytical techniques
Agitation and Mixing
Large scale mixing equipment
Mixing limited reaction
Mixing scale-up / scale-down

Quench & Work-Up
Liquid-liquid extractions
Phase continuity issues and emulsions
Distillation & Stripping
Differential distillation
Azeotropes and solvent exchange
Crystallization and Precipitation
Basic principles / yield estimation
Controlling supersaturation
Scale-up issues
Product Isolation and Drying
Large-scale solid-liquid separations
Filtration and drying equipment
Filtration and drying modelling
Process Hazards and Safety Assessment
Common hazards in large-scale processing
Process hazard assessments and evaluations

 

Benefits of attending

On completion of this course you will be able to:

  • Assess the safety and scalability of new processes
  • Identify process operations that may be problematic on scale-up
  • Design processes that will minimize or avoid common scale-up issues
  • Better understand heat transfer and mixing requirements for scale-up
  • Develop more robust crystallization, isolation and drying processes

 

 

Who should attend

This course has been designed for R&D chemists, engineers, technicians and managers in the pharmaceutical and fine chemical industries with limited pilot plant experience, who wish to learn more about the common pitfalls of process scale-up and ways to avoid them.the potential pitfalls of process scale-up and ways to avoid them.

What's Included

The course fee includes:

  • comprehensive course manual
  • coffee/tea refreshments breaks throughout each day
  • buffet lunch each day
  • course dinner on the first evening
  • course certificate

 

Testimonials

Hovione

Very helpful! Wish I could have done it sooner in my career! Thank you

Bayer Pharma AG

The course offers a lot of tips and tricks for successful scale-up. A must for every process chemist!

Givaudan

The course provided a very good overview of the different steps to be considered during the process development. Also a greater awareness of plant equipment.