Introduction
Scaling up a batch reaction from pilot to production scale often presents challenges that are not immediately evident
during development. Even when standard scale-up criteria such as geometric similarity and equivalent mixing time are
applied, differences in local hydrodynamics can significantly influence reaction selectivity and product quality. These
subtle variations—particularly in reactant distribution and concentration uniformity—are difficult to detect
experimentally but can have a substantial impact on competitive or fast reactions.
Mixing simulation provides a structured and reliable approach to evaluate these effects before and after scale-up. By
enabling engineers to visualize and quantify mixing behaviour across scales, VisiMix supports faster diagnosis of scale-up
deviations and helps identify actionable improvements.
In this newsletter, we highlight a real case study where a batch reactor scale-up led to increased by-product formation
despite matching mixing times. Using VisiMix Turbulent, the engineering team identified the underlying issue and
implemented a straightforward modification to the feeding strategy, resulting in a successful resolution.