Secrets of Batch Process Scale-Up

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The course aims to teach the practical aspects of designing a scaleable fine-chemical batch process and successfully implementing it at the kilo-lab and pilot plant scale, through an examination of the effects of large-scale operating methods and equipment limitations on process safety, operability, yield, selectivity and product quality.

The course presents an overview of scale-up phenomena 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.

Who Should Attend

  • Synthetic chemists
  • Process development chemists
  • Process engineers

in the pharmaceutical and fine chemical industries with limited pilot plant experience, who wish to learn more about the potential pitfalls of process scale-up and ways to avoid them.

Course Outline

  • Process Design for Scale-Up
  • Scale-Up – An Overview
  • Batch Reactors
  • Raw Materials
  • Temperature Control
  • Following Reaction Progress
  • Agitation and Mixing
  • Quench & Work-Up
  • Distillation & Stripping
  • Crystallization and Precipitation
  • Product Isolation and Drying
  • Process Hazards and Safety Assessment


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