SCALEUP

1
SCALE-UP

• THAT WHICH PROVES MURPHY TO BE AN OPTIMIST
• WHAT KEEPS ENGINEERING EMPLOYED
• WHAT NEVER COMES OUT AS EXPECTED

2
SCALE-UP

• IS COMPLEX AND NOT INTUITIVE
• IS GENERALLY A STEP-WISE APPROACH FROM LAB TO
  PILOT PLANT TO INTERMEDIATE TO FULL PRODUCTION
  SCALE
• REQUIRES CAREFUL ATTENTION TO ENGINERRING DETAILS

3
SCALE-UP

• REQIRES TECNOLOGY ASSESSMENT
• LEARN ON A SMALL SCALE BEFORE YOU TRY TO PRODUCE
  ON A LARGE SCALE
• THE LAB AND PILOT PLANT PROVIDE DESIGN DATA,
  ENGINEERING METHODS FIRST INDICATION OF
  FORMUATION PROCESSING INTERACTIONS

4
SCALE-UP

• REQUIRES COMPLETE UNDERSTANDING OF FACTORS THAT
  INFLUENCE PRODUCT CHARACTERISTICS
• CAN NOT BE DONE ON PAPER
• INVOLVES TECHNOLOGY TRANSLATION AND TRANSFER FROM
  RD TO PRODUCTION

5
ENGINEERING CONSIDERSTIONS

• ESSENTIAL UNIT OPERATIONS
• SEQUENCE OF OPERATIONS
• USE OF DIMENSIONLESS NUMBERS - REYNOLDS, NUSSELT,
  PRANDTL, ETC
• EQUIPMENT AVAILABLE
• NEW EQUIPMENT OR PROCESSES REQUIRED

6
EGINEERING CONSIDERATIONS

• JUST WHAT IS REQUIRED IN FLUID FLOW, HEAT
  TRANSFER?
• CAN PILOT PLANT EQUIPMENT ACTUALLY SCALE UP?
• WHAT ARE DIFFERENCES IN PILOT PLANT AND
  PRODUCTION EQUIPMENT THAT MAY BE CRITICAL?

7
PROCESS DESIGN CRITERIA

• NEEDED 6-12 MONTHS BEFORE COMMERCIAL PRODUCTION
  STARTS
• INCLUDES ALL DEVELOPMENT DATA AND INTERPRETATIONS
• INCLUDES TEMPERATURES, RESIDENCE TIMES, TYPES OF
  HEATING, AIR FLOW, MATERIALS, PUMPS, FLOW RATES,
  VELOCITIES, ETC.

8
TECHNOLOGY TRANSFER

• DETERMINE TRANSLATION VERSUS TRANSLATION NEEDS
• DISTILL INFORMATION THAT MAY BE WIDELY SCATTERED
  INTO A SINGLE ORGANIZED REPORT THAT BRINGS NEW
  PERSONEL UPTO DATE -IS A TEACHING TOOL AND A
  MEANS TO EXPAND COMPANYS TECHNOLOGY BASE

9
COMMERCIALIZATION

• START-UP
• SHAKE-DOWN -- EXPLORE PROCESS AND EQUIPMENT
  LIMITS -- LOOK FOR SUPRISES!
• PROCESS OPTIMZATION--NECESSARY TO CONFIRM THAT
  PROCESS HAS SCALED-UP PROPERLY

10
MUPHPYS LAWS

• ANYTHING THAT CAN GO WRONG WILL
• LEFT TO THEMSELVES, THINGS ALWAYS GO FROM BAD TO
  WORSE
• NATURE ALWAYS SIDES WITH THE HIDDEN FLAW
• IF ALL IS GOING WELL, YOU HAVE OVERLOOKED
  SOMETHING