Secrets of Batch Process Scale-Up: Ensuring Effective Translation of Laboratory Processes to Pilot Plant Scale
Event overview
This popular course, designed for those with limited or no pilot plant or scale-up experience, provides a comprehensive overview of the most common problems experienced during the scale-up of laboratory batch processes, and ways to avoid or mitigate them. The difference between laboratory scale techniques and how the major unit operations are carried out in the pilot plant is a key focus of the course. Thus, along the way attendees will examine the many issues associated with raw material handling, conducting synthetic reactions, reaction workup, product crystallization, isolation and drying at the pilot plant or commercial scale.
The course also explores some important engineering concepts such as batch mixing, heat transfer, mass transfer, fluid flow and the influence of these factors on the success of large scale chemical operations. With an awareness of these phenomena, the laboratory researcher will have a better understanding of the types of experiments that should be conducted and the types of data that should be collected to ensure a more successful scale-up. Numerous examples and case histories are presented to reinforce the course material, and class exercises provide an opportunity to put some of the lessons into practice. Heavy emphasis is placed on process safety.
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 chemists, engineers, technicians and managers in the fine chemical and pharmaceutical industries with limited pilot plant experience who wish to learn more about the potential pitfalls of process scale-up and ways to avoid them. Attendees will come away from the course more knowledgeable about common scale up problems and better equipped to prepare for and deal with them. The course complements the more chemistry-focused Scientific Update course “Chemical Development and Scale-Up in the Fine Chemical and Pharmaceutical Industries”.
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
As part of the registration fee for this course, each participant will receive a copy of The Pilot Plant Real Book – A Unique Handbook for the Chemical Process Industry, written by Mr. McConville.
Other Information
General Information
Each course includes:
- Refreshments & lunch daily
- Dinner on the first evening*
- The comprehensive Course Manual
- Course Certificate
- Pilot Plant book, by Fran McConville
Please refer to the course brochure for detailed timings.
*Not every course includes dinner please refer to the course brochures for detailed information on what’s included.
Course Certificate
At the end of each course participants receive a Certificate of Attendance.
Accommodation
Depending on venues we either reserve a limited number of bedrooms at a special rate for you or we will provide a list of recommended hotels close by to the course venue. More information on rates and booking forms will be provided upon booking. All rooms will need to booked directly with the hotel.
Discounts
1st delegate = full price
2nd delegate = 5% off
3rd delegate = 10% off
4 or more delegates = 15% off
For more information on discounts do give us a call on 44 1435 873 062
Brochure
View brochure
Venue info
Cambridge
MA 02142
United States
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