How to Scale-Up Chemical Processes

Manufacturing a chemical product is the next step after lab testing. Mass production is a thoroughly planned process. There is a scale-up methodology for chemical processes to guarantee the quality and quantity of the product and maintain the system’s integrity.

Choosing the Right Synthesis Route

The chemical process chosen to manufacture the product must be efficient in conserving energy, production time, conserving the environment, and cost-effective. It must also handle mass production and have the potential of scaling output when demand increases.

Factor in Reaction Kinetics

Scaling production also factors in the reaction rate of the chemical(s). Test the variables that influence the speed of a reaction to determine the best output rate. For instance, the process may warrant using catalysts to increase the reaction rate. It could also require minimizing by-products to maximize the production rate.

Understanding the Mixing and Mass of the Product Components

Scaling-up is impossible without the right mixing and mass of the product constituents.

When it comes to mass production, the quantity and availability of reacting elements influence the reaction rate and product quality. Therefore, having the right mixing unit and mass of reactants is vital to this process. It creates uniformity in the composition of the mixture or reaction; consequently, maintaining the product’s efficacy and reducing residue.

Consider the Logistics of Heat

Any chemical process produces heat. Calculate the amount of heat to be generated and include the dissipation rate in your equation. Furthermore, mass production is synonymous with increased heat production. The system should be able to handle this heat and have sufficient cooling processes.

Safety Tests

Aside from equipping the system with the needed components for producing large quantities, it is crucial to enforce safety measures. Assess all the production unit components by investigating outcomes through a simulation. The data from the virtual system will show the right conditions for optimum production. Do not forget to analyze the stability of the reactants, transfer processes, heat control, gas production, and the integrity of the final product.

VisiMix Video

The Influence of Mixing in the Process
New methodology using VisiMix software for the purpose of checking the influence of mixing in the processes.

VisiMix Demo Operation
Learning how to input data into the VisiMix software and get results the will help us understand the influence of mixing in our processes.

Lab Experiments
Learning how to set up the relevant experiments at the lab scale, to develop the processes from an engineering point of view.