Manufacturing process scale up in the personal care industry problems and solutions. Scaleup of cell culture bioreactors using biomechatronic design. Russell bernard and christopher mccarty at the university of florida. A production mixing unit is usually not geometrically similar to the mixer used for process development. Gallen, switzerland 2university of zurich, department chemistry, switzerland. In this study, a quality by design approach was applied to the design and scale up of a batch mixing process. Pilot plant scaleup techniques used in pharmaceutical. The experts across chemical industries agree that such modular plant concepts have large. Abstract in this article the authors, based on the visimix software, the experience of visimix users and personal. Jan 14, 2016 executive summary in scaleup, product and process development tend to move in small steps lab scale to bench scale, then to pilot scale, finally to production scale this reduces the risk with the larger investments in the next step scaledown is mainly for troubleshooting or development of processes used in ongoing production. Jun 02, 2010 since the first conference in 1994, the scale up of chemical processes has become the major international forum for the discussion of all these aspects of scale up and more in the pharmaceutical. Scaleup in chemical engineering pdf free download epdf. Scale up in chemical engineering pdf covering the important task of the scale up of processes from the laboratory to the production scale, this easily comprehensible and transparent book is divided. Chauvel, manual of economic analysis of chemical processes, mcgraw hill, new york, 1981.
It bases scaling on similarity principles and uses dimensional analysis to derive the dimensionless parameters necessary to ensure a successful chemical process development program. Process scaleup is the means by which innovations in the chemical industry are put into place in industrial facilities the vast majority of innovations in the chemical process industries are developed at laboratory scale at sizes better suited for careful measurement than for commercial operation. Scaleup suite is the worlds leading suite of drug substance process development and scaleup software for scientists and engineers working in the pharmaceutical industry. Taking a process or product from the bench to viable production scale is a complex task. The second element of our modelbased scaleup methodology is the use of hybrid models. A practical example 128 dr thierry meyer, swiss federal institute of technology, switzerland 9 route scouting and process development for 160 amino acid based chiral intermediates professor karlheinz drauz, degussa, germany 10 hazards of scaling up customers chemical processes 181. Conversion from laboratory scale tests to successful commercial size design bisio, attilio, kabel, robert l. If the equipment is too small the process developed will not scale up, whereas if equipment is too big then the wastage of the expensive active ingredients. He brings to this program fourteen years of teaching a highly successful scaleup course in the us and europe as. I bought this book hoping for some insight into scaleup, some new magic.
From laboratory to industrial scale scale up calculations of chemical processes for lca fabiano piccinno1,2 roland hischier1, stefan seeger2, claudia som1 1empa, technology and society lab, st. Chemical process scaleup and optimization services for future industrialscale production. An approximation to the scale up of batch processes using phenomenologicalbased models this work presents a methodology for scaling up batch processes bps using a phenomenologicalbased semiphysical model pbsm and the hankel matrix as tools for maintaining the operating regime or at each stage of the process when scaling it up. This is the authors version of the published article. This book discusses scaling chemical processes from a laboratory through a pilot plant to a commercial plant. M latimerb a astrazeneca, macclesfield works, sk10 2na macclesfield, uk b astrazeneca, avlon works,bs10 7ze, bristol, uk abstract we present a methodology to evaluate the robustness. Scientific update delivers conferences and training courses for industrial chemists and chemical engineers in chemical development, scale up and many other specialist topics in organic chemistry. If the equipment is too small the process developed will not scale up. Sep 22, 2008 an overview of the recent scale up conference in rome aimed at chemists and chemical engineers working in process chemistry, agrochemical, fine chemicals, flavour and fragrance. Experiences of scaleup of chemical processes by a 328 developing country in the field of pharmaceutical bulk substances. In addition, common basic methods are to be developed in the individual. Scale up and chemical process development taking a process or product from the bench to viable production scale is a complex task, often with critical consequences for the process owner. It is aimed both at university students and the process engineer.
Chemical engineering and chemical process technology vol. If you already have a demonstrated route and need it reproduced in a timely and efficient manner, our staff will meet or exceed your expectations. Helier jersey, channel islands conference proceedings conference organisers. A webinar presented by lubrizol focuses on how to improve process development and scale up by leveraging calorimetry and in situ process analysis. Technology development benefits from stage gates at which the viability of the technology can be assessed before continuing with the scale up scaling up step by step t he recommended approach for scaling bioenergy and biofuels technology follows a similar stage gate process to that used in traditional chemical process industry cpi processes. Fishbone diagrams also known as cause and effect diagrams or ishikawa diagrams are also used to identify causes associated with an event, but are easily adopted to identify hazards risks associated with an event. Outsourcing of the industrialization of a chemical process in a pilot plant. Key factors for bioprocess technology selection, scaleup and engineering of new facilities biocatalyst raw materials process technologies products scale economics s cale e conomics b. Samples were subsequently analyzed using nir reflection spectroscopy. Quality by design methodology for development and scaleup of. Eliminating unsafe and nongreen processes and materials. Introduction to chemical engineering processesprint version. The scale up of chemical processes is not such a trivial process and requires a certain understanding of the involved steps.
Such differences can make scale up from the laboratory or pilot plant challenging. Technology development benefits from stage gates at which. An effective process chemical scale up framework will deliver a solution that is fully optimised for safety, capitaloperating costs, capacity, performance and sustainability. They provide detailed scaleup steps for a variety of chemical applications.
Chemical reaction engineering, process design and scaleup. The second part presents the individual basic operations and covers the fields of mechanical, thermal, and chemical process engineering with respect to. Methods, aims and challenges of reconfigurable production plants 2. Scaleup andor scaledown procedures are crucial during the development of chemical processes. Scaleup of cell culture bioreactors using biomechatronic design carlfredrik mandenius and mats bjorkman linkoping university post print n. Nonlinear scale up is the number one challenge to pilot plant scale up and is the cause behind the other seven challenges. All this is illustrated by 20 realworld examples, while 25 exercises plus solutions new to this edition practice and monitor learning. Pdf chemical engineering design, principles, practice. Explain different concepts of scaleup in mixing and contacting pilot plant and scaleup studies dr. Iv development of chemical processes herbert vogel encyclopedia of life support systems eolss the starting point is the laboratory equipment and the outcome of development is the production plant. Process development, engineering and economics by edi d.
Until now no or few efforts seem to have been made to merge the two for efficient. Scientific update organic process chemistry training. Scale up methodology for the fine chemical industry the influence of the mixing in the process moshe bentolila visimix ltd. The network scale up method was developed by a team of researchers under grants from the u. Sadly, what i know, after 25 years of engineering is what ive gleaned from nature myself. Introduction chemical production is a result of several chemical reactions and purification steps. We also propose a possible methodology to design microchemical systems. However, many open issues can be evidenced regarding the true possibility of scale up, as well as currently lacking information for process design and economical evaluation. Executive summary in scaleup, product and process development tend to move in small steps lab scale to bench scale, then to pilot scale, finally to production scale this reduces the risk with the larger investments in the next step scaledown is mainly for troubleshooting or development of processes used in ongoing production. Standard textbooks often neglect topics like dimensional analysis, theory of similarity and scale up. Mixtures of acetaminophen and lactose were sampled at different mixing times using a groove sampler. B when citing this work, cite the original article.
Introduction to chemical engineering processesprint version from wikibooks, the opencontent textbooks collection contents hide 1 chapter 1. Manual of economic analysis of chemical processes, mcgraw. Scale up of specialty chemicals encompasses various design methods through which a small lab process typically at a gram scale is enlarged to a large scale process. Scale up methodology for the fine chemical industry the. Since the first conference in 1994, the scaleup of chemical processeshas become the major international forum for the discussion of all these aspects of scaleup and more in the pharmaceutical, fine chemical and allied fields. Process engineering for scaleup of specialty chemicals. Carlfredrik mandenius and mats bjorkman, scaleup of cell culture bioreactors using. Purification steps and processes yield are a direct function of the level of understanding of the reaction system. Industrial design, scaleup, and use of microreactors.
Get a quote download pdf version in the fine chemicals and pharmaceutical industries, the laboratory to semiindustrial scaleup phase is a. Scalability, the ability to function with different amounts of required work, or to be readily adjusted to do so. Product and process development for scaling up is typically move in small steps. Chemical engineering design, principles, practice and economics of plant and process design, second edition. The particle size distribution, residual solvent content and recovery yield were compared, showing that scale up is. From laboratory to industrial scale scaleup calculations of chemical processes for lca fabiano piccinno1,2 roland hischier1, stefan seeger2, claudia som1 1empa, technology and society lab, st. Along the way, we will identify and develop steps as appropriate for scale or safety considerations. Paul lambert laporte organics steve czapko mettlertoledo trevor laird scientific update ubtib hannover 124 581 919 89.
The guideline into which chemical process safety falls, is also known as hse or she guideline and included in the directives of many regulatory bodies. Producing small quantities of product for sensory, chemical, microbiological evaluations, limited market testing or furnishing samples to potential customers, shelflive and storage. Physical chemical biological methods, edited by hans schreier 116. Nonlinear scale up basically means you cannot take a chemical process in the lab and drop it into a pilot plant by simply increasing the chemicals and equipment involved in a proportionate manner. I bought this book hoping for some insight into scale up, some new magic. Mixing, chemical method, stirred tanks, batch chemical reactor, simulation, scale up, scale down. The strategic approach is a threestage process that countries can use to identify and prioritize their needs for reproductive health policy and programme development, test appropriate interventions to address priority needs and scale up successful initiatives. A chemical plant is an industrial process plant that manufactures or otherwise processes chemicals, usually on a large. Scaleup methodology for chemical processes jeanpaul euzen. Anticipation of scale up issues in pharmaceutical development. Chemical production is a result of several chemical reactions and purification steps. In teaching, the school offers process, bioprocess and chemical engineering courses in german and english. It now also contains information about scale up methods for pharmaceuticals.
A chemical plant is an industrial process plant that manufactures or otherwise processes chemicals, usually on a large scale. In addition to the organosolv process, the universal design of the pilot plant also enables other pulping methods for lignocellulose to be optimized on the pilot. A substantial number of reactions have been tested in microchemical systems. Pdf manufacturing process scale up in the personal care. Rd and scale up of chemical processes and has been an editorinchief of the american chemical society journal organic process research and. A novel industrial process for the manufacturing of hydromorphone from hydrocodone 4. Scaleup of chemical processes features the work of 17 renowned chemical engineersexperts in research, process development, manufacturing, and scaleup, from both industry and academiawho focus on the specific problems endemic to commercialization. Process engineering for scale up of specialty chemicals. We are here to help deliver solutions optimised for safety, performance and more.
An approximation to the scaleup of batch processes using. Determining the potential for scale buildup in processing equipment and methods to. Influencing mixing efficiency are the physical properties of the material being mixed, the design of the stirrer and the reactor, the mixing regime, and the position of the feed tube and the operating conditions. Datadriven, modelbased approaches to the scaleup, transfer and alignment of processes 12. Dimensional analysis and scaleup in chemical engineering. Scale up andor scale down procedures are crucial during the development of chemical processes. The effects of four processing parameters on the empirical mixing rate in a bin blender were examined. It presents dimensional analysis very comprehensively with illustrative examples of mechanical, thermal and chemical processes. Methodology for improvement of a management process. Scaleup in chemical engineering, 2nd edition marko. The methodology of process development leading to scaleup is the principal. Pilot plant scaleup techniques used in pharmaceutical manufacturing 1.
Scale up methodology for the fine chemical industry visimix. Purification steps and processes yield are a direct function of the level of. Pdf the dimdoe framework for scaleup in chemical engineering. Handbook of pharmaceutical analysis, edited by lena ohannesian and anthony j.
The scaleup of chemical processes is not such a trivial process and requires a certain understanding of the involved steps. Scale up chemical engineering in chemical engineering, the migration of a process from the lab scale to the pilot plant scale or commercial scale. Scaleup methodology for chemical processes jeanpaul. Scale up methodology for chemical processes by jeanpaul euzen, 9782710806462, available at book depository with free delivery worldwide. Pdf in chemical engineering dimensional analysis is a useful tool for. Rd and scaleup of chemical processes and has been an editorinchief of the american chemical society journal organic process research and. A practical innovation guide from idea to commercial implementation, second edition helps industrial process innovators in research, development and commercial startups assess the risks of commercialscale implementation, also providing them with practical guidelines and methods to reduce the risks to acceptable levels. Pdf this paper describes a recently developed methodology for modelbased scaleup and.
Process engineering for scaleup of specialty chemicals scale. Pilot plants and scale up of chemical processes is a must for all those who are, and wish to remain, expert in the field, providing for the first time in print, a comprehensive and unique perspective of pilot plant production. The main objectives of scale up activity at the centre are. Since the first conference in 1994, the scaleup of chemical processes has become the major international forum for the discussion of all these aspects of scaleup and more in the pharmaceutical, fine chemical and allied fields. At the heart of scaleup in chemical process development is the fundamental understanding of the mixing process. Chemical research and development, scaleup, process. These procedures should be integrated to form a multidisciplinary approach encompassing several. Scientific update delivers conferences and training courses for industrial chemists and chemical engineers in chemical development, scaleup and many other specialist topics in organic chemistry. The outlets from these zones are combined, and the flows of the medium blend to create a stream of some mixture temperature. The salient feature of the book is the fact that it addresses a subject which is vital in view of its economic repercussions. The method can be applied now to estimating the size of hardtocount or impossibletocount populations but the method is a work in progress. The subtle yet critical notion is that a newly engineered process is a scaledown replica of manufacturing at actual scale rather than a simple enlargement of a lab scale. Quality risk management qrm in pharmaceutical industry.
In this paper, we elaborated a framework that helps to scale up chemical production processes for lca studies when only data from laboratory experiments are available. Chemical process safety is part of a comprehensive safety assessment for scaleup and manufacturing and must therefore be regarded as part of the company culture and policy. Rushton 1951 has proposed a scaleup method for situations where the. Tatterson is a recognized leader in the areas of process scaleup, mixing and process design for industry. Introduction of scaleup processes by nurul saaadahsulaiman faculty of chemical and natural resources engineering. Anticipation of scale up issues in pharmaceutical development f. Preparation of large quantities typically x lab scale of materials having the same or similar chemical. The earlier that nonscalable conditions are recognized, the more easily a process can be modified with improvements for safety. The scaleup of chemical processes scientific update. Covering the important task of the scale up of processes from the laboratory to the production scale, this easily comprehensible. Automation manual operation has already almost completely given way for operation of all but the simplest pilot plants. However, limitations exist as numbering up in many cases can.