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Training Courses

Event 

Title:
Secrets of Batch Process Scale-Up
Subtitle:
Ensuring Effective Translation of Laboratory Processes to Pilot Plant Scale
When:
15.05.2012 - 17.05.2012
Tutors:
Where:
Sheraton Sand Key Resort - Clearwater Beach
Brochure:
View Brochure

Description

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”.

  • Course Outline
  • Objectives
  • On Completion
  • Who Should Attend?
  • Testimonials
  • 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 issues
     
    Batch Reactors
    Typical plant operations and equipment
    Characteristics of batch operations
     
    Raw Materials
    Raw material and route selection
    Large-scale charging methods and issues
     
    Temperature Control
    Large scale temperature control
    Heat transfer in batch reactors
    Controlling exothermic reactions
     
    Following 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 modeling
     
    Process Hazards and Safety Assessment
    Common hazards in large-scale processing
    Process hazard assessments and evaluations
     

  • Aims and Objectives?

    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.

    • Assess process safety and scaleability
    • Identify process operations that may be problematic on scale-up
    • Design processes that will minimize or avoid scale-up issues
    • Select operating methods and equipment for effective scale-up
    • Calculate heat removal rates and safe rates of addition of reagents
    • Determine mixing requirements for scale-up
    • Design crystallizations which can be successfully operated at scale
    • Predict the filterability of solid products upon scale-up
    • Minimize the effects of scale-up on yield, selectivity and product purity

  • This course has been designed for:

    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.

  • "Very informative - a lot of interesting and useful data. Good helpful case studies and an excellent manual." Lonza Ltd

    "Great course, very valuable for every chemist between R&D, pilot plant and plant."  Cytec Canada Inc

    "The tutor was very knowledgeable in all areas. He presented the material very well and kept the training very interesting with life experiences. One of the best instructors!"  Roche Colorado

Fee Info

Course Fee:
$1750
Multi Discount:
SAVE 5% for 2 attendees and 15% for 3 attendees

Venue

Sheraton Sand Key ResortMap
Venue:
Sheraton Sand Key Resort   -   Website
Street:
1160 Gulf Boulevard
Postcode / ZIP:
33767
City:
Clearwater Beach
State:
Florida
Country:
Country: us

Description

Situated on the Florida Keys with its own private beach and across the road from the shops of Sand Key, the Sand Keys Resort is in an ideal location for a business meeting, combined with excellent facilities for relaxation afterwards. The hotel has a fully equipped business centre, plus a variety of dining facilities. It has a state-of-the-art health club, plus outdoor recreational pursuits.

The hotel is holding standard rooms for us at a discounted rate. Scientific Update is contractually obligated to certain financial goals with the hotel.  Your reservation is greatly appreciated, as it helps to meet our agreement.  Please make your reservation soon in order to secure the reduced group rate.

Directions:

The hotel is easily accessible from Tampa or Orlando International Airports.
Shuttle services are available from the airports to the hotel.