Archived: Secrets of Batch Process Scale-Up

A 3 day training course

Date: 19 September - 21 September 2023

Location: Amsterdam, The Netherlands

Tutors: Francis X. McConville

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.



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!


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.

Online Johnson Matthey Delegate

This course included all unit operations that we are currently set up in our plant. All unit ops touch in this course and very helpful for us keep that in mind during the scale-up.

Online MilliporeSigma Delegate

The course quality was excellent. It was informative and covered a variety of useful topics. The instructor was clear, easy to understand, and open to share his knowledge and experience. The course gave me a new perspective on how to operate chemical processes in large-scale and what factors needs to be carefully screened in advance. I also found the cases and examples interesting and helpful in digesting the contents of the course.
The virtual training was a valuable experience and instructive.

Online Zentiva Delegate

Definitely a useful experience for anyone who is coming to the field of chemical Process development!


Online Event Enquiry

Archived: Secrets of Batch Process Scale-Up

This course is available as an online event upon request. Please provide your details and we will get back to you with further information.

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In-House Event Enquiry

Archived: Secrets of Batch Process Scale-Up

This course is available as an In-House event upon request. Please provide your details and we will get back to you with further information.

In-House Training Session

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